Method for additively manufacturing waveguide

Abstract

This invention discloses a radio frequency (RF) waveguide including a channel, a filter, and a support bridge. The channel may include an outer wall defining an inner cavity configured to propagate electromagnetic waves. The filter may be disposed within the inner cavity of the channel and may include a peripheral edge and an aperture. The support bridge may include a first interface at a first location connected to an inner surface of the outer wall, and a second interface at a location between the peripheral edge and the aperture of the filter to support the filter within the channel. The support bridge can remain in place connected to the filter, and the filter and waveguide can operate without interference from the support bridge, meaning that even when the support bridge remains in place, the waveguide meets all performance specifications and functions expected for a particular application.

Description

Prior Technology

[0001] Radio frequency waveguides, used for receiving and propagating electromagnetic radio waves, have a variety of applications in modern society. Traditionally, waveguides have been manufactured using casting and other manufacturing processes to produce multiple components that are subsequently assembled using welding, brazing, fasteners, and / or washers to form a single waveguide. Additive manufacturing (e.g., 3D printing) has begun to be used to manufacture small-scale waveguides. However, due to challenges such as manufacturing defects, surface roughness, and stitching errors arising from using large-scale printers containing multiple print sources for producing 3D-printed waveguides, large-scale 3D printers pose a challenge to the manufacture of large-scale waveguides (e.g., C-band waveguides) using additive manufacturing.

[0002] For example, due to their larger scale, large waveguides are more prone to manufacturing defects, such as warping of the face-down surface during manufacturing, compared to smaller waveguides. Typically, during manufacturing, internal support structures are used in smaller waveguides to support the waveguide surfaces and structures that are particularly susceptible to manufacturing defects during the stacking process. However, to avoid interfering with waveguide operation, these internal support structures are usually removed after manufacturing via an additional material removal process, thereby increasing the cost, complexity, and time of waveguide manufacturing, as well as the chance of defects forming in the waveguide.

[0003] Additionally, large-format printers can use multiple print sources (e.g., inkjet, combined jet, extruder, laser, electron beam, or other heating devices used in powder bed melt deposition modeling) to form a waveguide in a laminated fabrication. Misalignment of multiple print sources can lead to incorrect and / or incomplete formation of components in a stitched area where the print ranges of the print sources overlap. For example, if overlapping print sources are misaligned, multiple print sources may print in an area where only one print source is used to form a component, resulting in an unintended excess of material in the misaligned section and component deformation. Alternatively, due to misalignment, all print sources may fail to properly form a waveguide in a particular area, thereby leaving unintended gaps and spaces in the waveguide walls that can adversely affect waveguide performance.

[0004] Due to the aforementioned problems in the fabrication of large-scale waveguides, we continue to seek new designs for large waveguides and new methods for manufacturing them to reduce lead time, cost and complexity, while ensuring the reliable performance and fabrication of such large waveguides. Summary of the Invention

[0005] The following provides an initial overview of one of the concepts of the invention, followed by a detailed description of specific examples. This initial summary is intended to help the reader understand the examples more quickly, but is not intended to identify key or essential features of the examples, nor is it intended to limit the scope of the subject matter.

[0006] The examples disclosed herein are examples of various configurations included in the teachings herein. Although the invention may not explicitly disclose that some examples or features described herein can be combined with other examples or features described herein, the invention should be understood to describe any such combinations that can be practiced by those skilled in the art. Furthermore, the described features, structures, or characteristics can be combined in any suitable manner in one or more of the examples described herein.

[0007] Example 1 illustrates a waveguide manufactured using a multilayer fabrication process. The waveguide may include a channel, a filter, and a support bridge supported within the channel. The channel may include an outer wall defining an inner cavity configured to propagate electromagnetic waves. The filter may be disposed within the cavity of the channel and may include a peripheral edge and an aperture. The support bridge may include a first interface at a first location connected to an inner surface of the outer wall, and a second interface at a location between the peripheral edge and the aperture of the filter to support the filter within the channel. During use of the waveguide, the support bridge may remain in place connected to the filter, and the filter may operate without interference from the support bridge. This means that the support bridge can be formed within the RF waveguide such that the RF waveguide meets all performance specifications and functions intended for a particular application even when the support bridge remains in place.

[0008] Example 2 is based on one of the waveguides in Example 1, wherein the waveguide is integral.

[0009] Example 3 is a waveguide according to any one of Examples 1 and 2, wherein the filter includes an iris filter having an aperture formed therein, wherein the second interface of the support bridge is connected to the plate.

[0010] Example 4 is a waveguide based on any one of Examples 1 to 3, which further includes a transition surface formed between the first interface and the inner surface, and a transition surface formed between the second interface and the filter.

[0011] Example 5 is a waveguide according to any one of Examples 1 to 4, wherein the support bridge further includes a third interface connected at a second location to one of the inner surfaces of the outer wall.

[0012] Example 6 is based on any one of Examples 1 to 5, wherein the filter operates without interference from the support bridge, meaning that the support bridge can be formed within the RF waveguide such that even if the support bridge remains in place, the RF waveguide still meets all the performance specifications and functions expected for a particular application.

[0013] Example 7 is a waveguide according to any one of Examples 1 to 6, which further includes a transition surface formed between the third interface and the inner surface.

[0014] Example 8 is a waveguide based on any one of Examples 1 to 7, wherein the channel includes a substantially rectangular cross-section and the outer wall includes four sides configured in a rectangular shape.

[0015] Example 9 is a waveguide according to any one of Examples 1 to 8, which further includes a plurality of support bridges having the support bridge, each including a first interface connected at its respective location to an inner surface of the outer wall, and a second interface connected at a location between the peripheral edge and the aperture of the filter to support the filter within the channel, wherein the plurality of support bridges are offset from each other.

[0016] Example 10 is based on any one of Examples 1 to 9, wherein the supporting bridge is substantially herringbone shaped.

[0017] Example 11 is a waveguide according to any one of Examples 1 to 10, wherein the waveguide is manufactured by a multilayer fabrication system.

[0018] Example 12 is a waveguide according to any one of Examples 1 to 11, wherein the stacking fabrication system includes two or more printing sources, each printing source printing in a region shared by the two or more printing sources. The waveguide may further include a band formed around the outer wall and disposed in a stitched region of the waveguide, configured to be printed by the stacking fabrication system in the region shared by the two or more printing sources.

[0019] Example 13 is a method for fabricating waveguides 1 to 12 of the above examples using a multilayer fabrication system. The method may include providing a fabrication plate including a base and one or more fabrication surfaces extending from the base (e.g., the fabrication surfaces may be oriented at an angle relative to the base). The method may further include continuously layering material on the fabrication plate in a fabrication direction perpendicular to one of the surfaces of the base. The method may further include forming a channel including an outer wall defining an inner cavity configured to propagate electromagnetic waves. The method may further include forming a filter disposed within the inner cavity of the channel, the filter including a peripheral edge, an aperture, and a downward-facing surface of the base relative to the fabrication plate. The method may further include forming a support bridge including a first interface connected at a first location to an inner surface of the outer wall, and a second interface connected at a location between the peripheral edge of the filter and the aperture in the filter to support the downward-facing surface of the filter within the channel.

[0020] Example 14 includes the method of Example 13, wherein the stacking fabrication system includes two or more printing sources, each printing source printing in a region shared by the two or more printing sources. The method may further include forming a band around the outer wall in a stitched region of the waveguide, configured to print in the region shared by the two or more printing sources.

[0021] Example 15 is a method of any one of Examples 11 and 14, wherein the one or more building surfaces are oriented at 45 degrees relative to the base.

[0022] Example 16 is a method of any one of Examples 11 to 15, which further includes forming the support bridge to remain in place during operation of the waveguide.

[0023] Example 17 is a method of any one of Examples 11 to 16, further comprising forming a plurality of support bridges including the support bridge, each including a first interface connected at a respective location to an inner surface of the outer wall, and a second interface connected at a location between the peripheral edge and the aperture of the filter to support the filter within the channel, wherein the plurality of support bridges are offset from each other.

[0024] Example 18 is a method of any one of Examples 11 to 17, wherein the waveguide is integral.

[0025] Example 19 is a method of any one of Examples 11 to 18, wherein the filter includes an iris filter having an aperture formed therein and the second interface of the support bridge is connected to the plate.

[0026] Example 20 is a method of any one of Examples 11 to 19, which further includes configuring the support bridge to further include a third interface connected to one of the inner surfaces of the outer wall at a second location.

[0027] Example 21 is a method of any one of Examples 11 to 20, which further includes forming a transition surface between the first interface and the inner surface, and forming a transition surface between the second interface and the filter.

[0028] Example 22 is a method of any one of Examples 11 to 21, which further includes forming a transition surface between the third interface and the inner surface.

[0029] Example 23 is a method of any one of Examples 11 to 22, wherein the channel includes a substantially rectangular cross-section and the outer wall includes four sides configured as a rectangular shape.

[0030] Example 24 is a method of any one of Examples 11 to 23, wherein the supporting bridge is substantially herringbone shaped. Simple Explanation of the Diagram

[0031] The features and advantages of the present invention will be apparent from the following detailed description, which is illustrated by way of example and the accompanying drawings; and, wherein:

[0032] Figure 1a illustrates an isometric view of a waveguide formed using a stacking fabrication process according to an embodiment of the present invention.

[0033] Figure 1b shows a cross-section of one channel of the waveguide in Figure 1a.

[0034] Figure 2a shows a top view of one of the waveguides in Figure 1a.

[0035] Figure 2b shows a top view of one of the waveguides in Figure 1a.

[0036] Figure 3a shows a first side view of one of the waveguides in Figure 1a.

[0037] Figure 3b shows a second side view of one of the waveguides in Figure 1a.

[0038] Figure 4a shows a rear view of one of the waveguides in Figure 1a.

[0039] Figure 4b shows a front view of one of the waveguides in Figure 1a.

[0040] Figure 5a shows a cross-sectional view of the waveguide of Figure 1a taken along line AA of Figures 3a and 3b.

[0041] Figure 5b shows a close-up cross-sectional view of region C of the waveguide in Figure 1a, obtained along the dashed line shown in Figure 5a.

[0042] Figure 6a shows a cross-sectional view of the waveguide in Figure 1a obtained along line BB in Figure 4b.

[0043] Figure 6b shows a close-up cross-sectional view of region D of the waveguide in Figure 1a, obtained along the dashed line shown in Figure 6a.

[0044] Figure 7 shows a partial perspective view of the waveguide in Figure 1a, with one wall removed to show the internal components of the waveguide.

[0045] Figure 8a shows a partial side view of the waveguide of Figure 1a, with one wall removed to show the internal components of the waveguide.

[0046] Figure 8b shows a partial perspective view of the waveguide in Figure 1a, with one wall removed to show the internal components of the waveguide.

[0047] Figure 9 illustrates a support bridge that can operate within the waveguide of Figure 1a, according to an alternative embodiment of the present invention.

[0048] Figures 10a, 10b and 10c respectively illustrate a top view, a side view and a front view of a support bridge that can operate within the waveguide of Figure 1a according to an alternative embodiment of the present invention.

[0049] Figure 11a illustrates the front and side views of the waveguide filter and support bridge of Figure 1a positioned relative to each other.

[0050] Figure 11b illustrates an alternative configuration of the support bridge for supporting a filter according to an example of the present invention, such support bridge being operable within the waveguide of Figure 1a.

[0051] Figure 12 illustrates a construction board for manufacturing one of a plurality of waveguides according to an example of the present invention, using the waveguide shown in Figure 1a.

[0052] Figures 13a and 13b show side views of the waveguide of Figure 1a on the building board and away from the building board.

[0053] Figure 14 shows a top view of one of the construction boards in Figure 12.

[0054] The exemplary embodiments illustrated in the figures will now be referred to, and these embodiments will be described herein using specific language. However, it should be understood that this is not intended to limit the scope of the invention. Implementation

[0055] Related applications This application claims the rights of U.S. Provisional Patent Application No. 63 / 295,447, filed December 30, 2021, the entire contents of which are incorporated herein by reference.

[0056] As used herein, the term "substantially" refers to the extent or degree of completeness or near-completeness of an action, characteristic, property, state, structure, item, or result. For example, "substantially" enclosing an object means that the object is completely or almost completely enclosed. In some cases, the exact permissible degree of deviation from absolute completeness may depend on the specific context. However, in general, the degree of near-completeness will have the same effect as achieving the overall result of absolute and complete completion. The use of "substantially" also applies in a negative sense to refer to the complete or near-complete lack of an action, characteristic, property, state, structure, item, or result.

[0057] As used herein, "adjacent" refers to the proximity of two structures or elements. Specifically, elements identified as "adjacent" may be adjacent or connected. These elements may also be close to or near each other without necessarily touching. In some cases, the exact degree of proximity may depend on the specific context.

[0058] To further describe the present technology, examples are now provided with reference to the figures. Referring to Figure 1a, a waveguide 100 configured to be manufactured by multilayer fabrication according to an embodiment of the present invention is illustrated. The waveguide 100 may include a hollow channel 102 that propagates electromagnetic waves in radio waves and microwave frequencies of the electromagnetic spectrum therein (hereinafter collectively referred to as "radio waves" or "radio frequency" (RF)). The waveguide 100 (which may also refer to an RF waveguide) may include a series of waveguide features or components forming a continuous channel 102 for propagating radio waves. The waveguide features or components may be, for example, outlet / inlet ports, including a port 104 formed on one side of the waveguide 100, a port 105 formed on one side of the waveguide 100 opposite to the port 104, a port 106 formed on one front side of the waveguide 100, a port 108 formed on one side of the waveguide 100, and a port 110 formed in an upper flange 112 of the waveguide 100. Ports 104, 106, 108 and 110 can be wave or fluid connected to each other through channel 102 to propagate radio waves throughout waveguide 100.

[0059] Channel 102 may further include U-shaped bends 114 and 116 that rotate one path of a wave by 180 degrees, bends 118 and 120 that rotate one path of a wave by 90 degrees, and / or a T-joint 122 that branches or combines waves in multiple directions of channel 102. Waveguide 100 may further include a thickened strip 124 disposed on a portion of waveguide 100. Strip 124 will be described in more detail below with reference to the fabrication of waveguide 100 using a multilayer fabrication system comprising a plurality of print sources.

[0060] Those skilled in the art will understand that the principles described herein can be applied to any waveguide containing any number or configuration of features, bends, joints, ports, lengths, and / or strips in any combination without departing from the scope of the invention. Waveguides formed according to the principles described herein are not intended to be limited in any way to the example waveguide 100 described herein.

[0061] Referring to Figure 1b, the figure shows a cross-section of port 104, which in turn shows a cross-section of channel 102. Although the specific cross-section shown in the figure is the cross-section of port 104, the cross-section of channel 102 will look similar anywhere along the path P of waveguide 100. As shown in Figure 1b, channel 102 may have a rectangular cross-section along a portion or the entire length of the propagation path P of channel 102.

[0062] As shown in Figure 1b, a rectangular cross-section may include a first dimension a and a second dimension b, which equally define the height and width of an inner cavity 126 of channel 102. The ratio of dimension a to dimension b defines the aspect ratio of channel 102. Although dimension a is shown to be larger than dimension b, it should be understood that the dimensions of channel 102 are not intended to be limited in any way. Dimension b may be larger than dimension a, or dimensions a and b may be equal to form a square channel 102. The aspect ratio of channel 102 is not intended to be limited in any way by the present invention. The inner cavity 126 may be defined by an outer wall 128. The outer wall 128 may include a plurality of adjacent sides, including sides 128a, 128b, 128c, and 128d. Sides 128a, 128b, 128c, and 128d together form the outer wall 128 of channel 102 and define the inner cavity 126. The outer wall 128 may include an inner surface 129 through waveguide 100. In addition, the cross-section of channel 102 is not limited to rectangle and may include any known shape or configuration of channel other than rectangle (e.g., circular, oval, or any other shape of any size or dimension).

[0063] Referring to Figures 2a, 2b, 3a, 3b, 4a, and 4b, various alternative views of waveguide 100 are shown. Figure 2a shows a top view of waveguide 100. Figure 2b shows a bottom view of waveguide 100. Figure 3a shows a side view of waveguide 100. Figure 3b shows a side view of waveguide 100. Figure 4a shows a rear view of waveguide 100. Figure 4b shows a front view of waveguide 100. In all views of Figures 1a, 1b, 2a, 2b, 3a, 3b, 4a, and 4b, the internal configuration of channel 102 is obstructed by the outer wall 128 of waveguide 100 and cannot be viewed. To explain and describe the internal configuration of waveguide 100, various cross-sectional views are obtained along lines AA, BB, and CC of Figures 2a, 3a, 3b, and 4b.

[0064] Referring to Figure 5a, a cross-sectional view of waveguide 100 is shown along line AA as shown in Figures 3a and 3b. Figure 5b shows a close-up view of region C in Figure 5a, which is a front view of waveguide 100 showing the internal configuration of the T-joint 122 of waveguide 100.

[0065] As shown in Figure 5b, a filter 130 is disposed within channel 102, extending between sides 128a and 128d of channel 102 and at least partially supported by sides 128a and 128d of channel 102. A support bridge 132 is also formed in channel 102 to support filter 130 within channel 102. Support bridge 132 may include a first interface 132a connected to an inner surface 129 of outer wall 128 at a first location (e.g., side 128d), a second interface 132b connected to filter 130, and a third interface 132c connected to an inner surface 129 of inner wall 128 at a second location (e.g., side 128a).

[0066] As shown in the figure, waveguide 100 may further include a phantom T-joint 133 disposed at one intersection of T-joint 122. Phantom T-joint 133 facilitates the propagation of radio waves through waveguide 100 and particularly helps guide and direct radio waves through T-joint 122.

[0067] The support bridge 132 has a configuration and is positioned such that, after the waveguide 100 is manufactured, the support bridge 132 can remain in its original position connected to the filter 130 without interfering with the operation of the filter 130, the phantom T-junction 133, or the waveguide 100. This means that the support bridge 132 can be formed within the waveguide 100 such that even with the support bridge 132 in place, the waveguide 100 meets all performance specifications and functions intended for a particular application. Therefore, using the support bridge 132 as described herein, the waveguide 100 can be printed in a single stacking fabrication process to form the waveguide 100 as a single monolithic component without the need for additional individual components to form an assembly.

[0068] In this invention, the term "monolithic" encompasses any structure printed as a single, monolithic component using laminated fabrication. A "monolithic" structure (e.g., a waveguide) can be a single-material monolithic structure manufactured by a laminated fabrication system capable of printing a monolithic structure using a single material throughout the structure. Alternatively, "monolithic" can also refer to a multi-material structure (e.g., a waveguide) manufactured by a laminated fabrication system capable of printing a monolithic structure using two or more materials during a single laminated fabrication process.

[0069] Furthermore, because the support bridge 132 can remain in place without interfering with the operation of waveguide 100 or any of its components, it is not necessary to remove the internal support structure within waveguide 100. Therefore, there is no need to perform a post-manufacturing removal procedure on waveguide 100 to remove the internal support structure, thereby reducing the cost, lead time, manufacturing, and complexity of waveguides formed according to the concepts disclosed herein.

[0070] The support bridge 132 can be any suitable shape that will not interfere with the operation of the waveguide 100. Using three interfaces 132a, 132b, and 132c, the support bridge 132 can be a substantially herringbone shape as illustrated in the figure. The herringbone shape can be defined by a height h, a width w, and an angle g between the arms of the support bridge 132. It should be understood that the dimensions of the herringbone shape are not intended to be limited in any way by the present invention. For example, the height h can be greater than the width w, the width w can be greater than the height h, or the width and height can be equal. Similarly, the angle g can be any desired measurement. The ratio of h to w defines an aspect ratio of the herringbone shape. The aspect ratio is not intended to be limited in any way by the present invention. In addition, the arms of the herringbone shape can have any desired width or length. However, this shape and the accompanying disclosure are not intended to be limited in any way. The support bridge 132 may be any suitable shape including triangle, rectangle, square, circle or any other suitable shape or configuration (including shapes or configurations with any number of sides and interfaces).

[0071] Referring to Figure 6a, a cross-sectional view of waveguide 100 taken along line BB shown in Figure 4b is illustrated. Figure 6b shows a close-up view of region D in Figure 6a, which, from a bottom view of waveguide 100, shows the internal configuration of the T-junction 122 of waveguide 100. As shown in Figure 6b, filter 130 may include a plate 134 having a peripheral edge 135 that can interface with the sides 128a, 128b, 128c, and 128d of outer wall 128. An aperture 136 may be formed in plate 134 of filter 130. Filter 136 may be any known filter used in waveguides for filtering out specific types (e.g., polarization, wavelength, or frequency) of radio waves and allowing the desired radio waves to pass through filter 130. Filter 130 shown in the figure may be an iris filter in which a rectangular aperture is formed. A rectangular aperture can be defined by a first dimension c and a second dimension d, where the first dimension c indicates the length of a first side of the aperture, and the second dimension d indicates the length of a second side of the aperture. The ratio of the first dimension c to the second dimension d defines the aspect ratio of the aperture. However, the size of the aperture is not intended to be limited by this invention. Dimension c may be larger than dimension d, dimension d may be larger than dimension c, or dimensions c and d may be equal to define a square aperture. Furthermore, the aspect ratio of the aperture is not intended to be limited in any way and can be any aspect ratio. However, this particular type of filter and / or filter configuration is not intended to be limited in any way. Any known filter supported in a waveguide channel can be used without departing from this invention. Additionally, any known shape or configuration of aperture other than rectangular (e.g., circular, oval, or any other shape of any size or dimension) can be formed in the filter without departing from this invention.

[0072] Referring to Figures 7, 8a, and 8b, various perspective views of the filter 130 and support bridge 132 within channel 102 of waveguide 100 are shown. Figure 7 shows a perspective view of a cross-section of Figure 5b. As shown in Figure 7, the third interface 132c of support bridge 132 can be connected to the inner surface 129 of outer wall 128 at side 128a. The first interface 132a of support bridge 132 can be connected to the inner surface 129 of outer wall 128 at side 128d, and the second interface 132b of support bridge 132 can be connected to plate 134 of filter 130.

[0073] Figures 8a and 8b are constructed at one of 45-degree orientations, which will be described later with respect to the manufacturing method used for waveguide 100. For the purposes of this discussion, Figures 8a and 8b are provided to illustrate the configuration and interface between the support bridge 132 and the filter 130 within waveguide 100. Figure 8a shows a side view of a cross-section of waveguide 100 taken along line CC of Figure 2a. Figure 8b shows a perspective view of a cross-section of Figure 8a. As shown in Figure 8b, the support bridge 132 can interface with the plate 134 of filter 130. The first interface 132a can be connected to the inner surface 129 of the outer wall 128 at side 128d (shown in FIG. 5b), the third interface 132c of the support bridge 132 can be connected to the inner surface 129 of the outer wall 128 at side 128a (shown in FIG. 8b), and the second interface 132b can be connected to the plate 134 at a position between the peripheral edge 135 and the aperture 136 of the filter 130 to support the filter 130 within the channel 102.

[0074] Alternative configurations of the support bridge are envisioned and are intended to be within the scope of this invention. Referring to Figure 9, an alternative support bridge 932 is illustrated. Similar to support bridge 132, support bridge 932 can be placed within waveguide 100 at any location where a filter can be placed within channel 102 (e.g., T-junction 122). Figure 9 illustrates support bridge 932 supporting filter 130 within channel 102. As shown, support bridge 932 may include two interfaces. Interface 932a of support bridge 932 can be connected to inner surface 129 of channel 102 at side 128d, and interface 932b of support bridge 932 can be connected to a plate at a location between the peripheral edge of filter 130 and the aperture of filter 130 to support filter 130 within channel 102. To save material and space occupied by the support bridge within channel 102, the support bridge 932 may contain only two interfaces, as depicted in the figure, resulting in a smaller surface area and less material used to support the filter 130 during waveguide fabrication and operation.

[0075] According to an embodiment of the present invention, the support bridge can be configured in various ways to interface with the filter 130 and the outer wall 128. FIG10a illustrates a top view of the support bridge 132. As shown in the figure, the interface 132b connected to the filter 130 may include a pair of transition surfaces 138a and 138b formed at the interface 132a between the filter 130 and the support bridge 132. The transition surfaces 138c and 138d may be further formed at the interface 132a and 132c between the sides 128a and 128d of the support bridge 132 and the outer wall 128. Although the surfaces 140a and 140b shown in FIG10a do not show rounding or blending with the transition surfaces, it should be understood that the transition surfaces may be formed at interfaces 132a, 132b and 132c or at any desired location along interfaces 132a, 132b and 132c.

[0076] Although the transition surface shown in Figure 10a is formed in only one plane (e.g., the plane of support bridge 132), it should be understood that the transition surface can be formed on any plane orientation in which support bridge 132 interfaces with outer wall 128 or filter 130. For example, Figures 10b and 10c illustrate transition surfaces 142a and 142b formed in one of the planes perpendicular to the plane of support bridge 132 at interface 132b. Figure 10c further illustrates transition surfaces 142a and 142b formed at locations outside aperture 136 on plate 134 to avoid any obstruction of aperture 136 that could interfere with the operation of filter 132 in waveguide 100 during operation.

[0077] To avoid potential surface roughness and manufacturing defects, it is preferable to limit the size of the transition surfaces, specifically the downward-facing transition surfaces (such as 142a and 142b), as large downward-facing transition surfaces are prone to defects. For example, it is preferable that each downward-facing transition surface has a radius of less than 2 inches. More preferably, the radius is between 0.05 inches and 0.15 inches. However, the present invention is not intended to limit the size of the transition surfaces in any way, and any size of the transition surfaces is within the scope of the present invention.

[0078] Furthermore, although Figure 10b shows transition surfaces 142a and 142b formed only below the support bridge 132, it should be understood that transition surfaces can be formed on the top, bottom, sides, or all sides of the support bridge 132. Any number of transition surfaces can be formed at any location around interface 132b. Additionally, a continuous transition surface can be formed at all portions where one of the interfaces intersects with the outer wall 128 or plate 134 of the filter 130.

[0079] Transition surfaces are formed at any one or more of the interfaces 132a, 132b, and 132c of the support bridge 132 to grade the transition between the support bridge 132 and the filter 130 and the outer wall 128. In the fabrication of waveguides, abrupt and sudden changes in surface orientation at the interfaces can cause deformation, such as evidence lines, surface roughness, or undesirable protrusions that can adversely affect wave propagation in the waveguide 100 and the overall operation and performance of the waveguide. Adding transition surfaces at the time of abrupt changes in surface orientation can mitigate these problems and reduce deformation and manufacturing defects. It should be understood that transition surfaces may include a circle, a chamfer, a fillet, or other known transition surface configurations, and any possible combination thereof. Therefore, the circles shown in the figures and discussed herein are not intended to limit in any way.

[0080] As described above, the support bridge 132 is positioned or located in a location between the aperture 136 of the filter 130 and the peripheral edge 135 of the plate 134 (i.e., intersecting with the filter 130). As shown in Figure 10c, when viewed perpendicularly to the plate 134, no part of the support bridge overlaps with the aperture 136 of the filter 130. Figure 11a illustrates a front view and a side view of the filter 130, in which the support bridge 132 is positioned and supports the filter 130.

[0081] An aperture 136, including a hole passing through a plate 134, may be defined by a plurality of surfaces of the plate 134. The aperture 136 may be defined by an upper surface 136a, two side surfaces 136b and 136c, and a lower surface 136d. In some embodiments, the lower surface 136a may be parallel to the upper surface 136b. In the example shown in the figures, a support bridge 132 may be mounted on the plate 134 such that a bottom surface 137 of the support bridge 132 is positioned outside the aperture 136 between the aperture 136 and the peripheral edge 135 of the plate 134 of the filter 130. In this example, the bottom surface 137 of the support bridge 132 is substantially aligned with the upper surface 136a that partially defines the aperture 136. Therefore, the bottom surface 137 of the support bridge 132 and the upper surface 136a that partially defines the aperture 136 form a continuous surface, thus providing a smooth, uninterrupted surface on which radio waves can propagate without interference. The support bridge 132 can be positioned anywhere outside the aperture 136 between the aperture 136 and the peripheral edge 135 of the plate 134 of the filter 130, and does not need to be positioned adjacent to the edge or upper surface 136a of the aperture 136, or aligned with the edge or upper surface 136a of the aperture 136, as shown in the example.

[0082] According to this configuration, radio waves propagating through aperture 136 are not disturbed or interfered with by support bridge 132. As shown in Figure 8a, radio waves RW moving through aperture 136 of filter 130 can flow through aperture 136 without obstruction by support bridge 132 and reach phantom T-junction 133. Therefore, support bridge 132, positioned between aperture 136 and the peripheral edge 135 of plate 134 of filter 130, ensures that support bridge 132 does not cause interference to filter 130 or phantom T-junction 133, and thus does not interfere with the performance of waveguide 100. Support bridge 132 can be designed to remain in place after all manufacturing processes are completed, thus eliminating the additional cost and time consumed by post-printing removal procedures, which would otherwise be used to remove support bridge 132.

[0083] Within the scope of this invention, additional configurations of the support bridges are possible. For example, a plurality of support bridges may be formed to support filter 130. Figure 11b illustrates an alternative configuration of support bridges on a filter. For example, filter assembly 1100 illustrates a configuration in which a plurality of support bridges 1132a and 1132b are formed to interface with and support filter 1130, filter 1130 may include a configuration identical to that of filter 130 discussed above. Filter assembly 1100 may include an upper support bridge 1132a and a lower support bridge 1132b, both of which are disposed between aperture 1136 and the peripheral edge of plate of filter 1130, and in this example, are aligned with one of the upper surface 1136a and the lower surface 1136b of aperture 1136 in filter 1130. The upper and lower support bridges 1132a and 1132b may also refer to the first and second support bridges 1132a and 1132b to avoid confusion regarding any orientation relative to each other. Furthermore, support bridges 1132a and 1132b may be configured as any of the support bridges discussed and disclosed herein (or based on the concepts disclosed herein).

[0084] Filter assembly 1102 is illustrated in which a plurality of support bridges 1132a and 1132b are formed to interface with and support one configuration of filter 1130. Filter assembly 1102 may include a first support bridge 1132a and a second support bridge 1132b, both of which are positioned on one side and outside of the aperture 1136 in filter 1130 between the aperture 1136 and the peripheral edge of filter 1130. The second support bridge 1132b may be offset from the first support bridge 1132a and positioned between the peripheral edge of filter 1130 and the first support bridge 1132a.

[0085] Any number of desired support bridges, as described herein, can be formed on filter 1136 to provide support. Additionally, support bridges 1132a and 1132b may each include a herringbone support bridge (in one instance, such as support bridge 132, or as another instance, a strip support bridge 932, or a support bridge of any shape according to the invention). As described elsewhere in the invention, each of the plurality of support bridges may include a first interface connected to an inner surface of an outer wall, and a second interface connected to the filter at a location between the peripheral edge of the filter and the aperture to support the filter within the channel. As illustrated, the plurality of support bridges may be offset from each other.

[0086] Methods and approaches for manufacturing waveguides will be described with reference to Figures 12 through 14. Figure 12 illustrates an isometric view of a multilayer fabrication system 1200 for manufacturing one waveguide 1202 and one waveguide 1204, which may include any of the waveguide examples discussed herein (such as the waveguides discussed relative to Figures 1A through 11B). System 1200 may include a build plate 1206 having a base 1208 and a plurality of build surfaces 1210 formed thereon of waveguides 1202 and 1204. In the multilayer fabrication of the waveguide, the method may include providing a build plate having one or more build surfaces for forming one or more of the waveguides 1202 and 1204. The method may further include continuously layering material on the build plate in a build direction perpendicular to one of the build surfaces 1212 of the base 1208 of the substrate 1206.

[0087] The method may further include forming a channel comprising an outer wall defining an inner cavity configured to propagate electromagnetic waves. The method may further include forming a filter disposed within the cavity of the channel, the filter comprising a peripheral edge, an aperture, and a downward-facing surface relative to a base of a building plate. The method may further include forming a support bridge comprising connecting at a first location to a first interface of an inner surface of the outer wall, and at a location between the peripheral edge of the filter and the aperture in the filter to a second interface of the filter to support the downward-facing surface of the filter within the channel. During the successive layering of material on the building plate, the steps for forming the components of a waveguide as described in this invention may be performed. Furthermore, the method may include forming a thickened material strip around the exterior of the waveguide. The thickened strip will be described in more detail below with reference to FIG14.

[0088] Figure 13 illustrates a side view of waveguides 1202 and 1204 on the build surface 1210 of the build plate 1206. Figure 13 shows a build direction BD, in which the material is continuously layered on the build plate 1206. The build direction BD may be parallel to the pull of gravity and perpendicular to one surface of the base 1206. As shown, the build surface and waveguides 1202 and 1204 are oriented at an angle relative to the build direction BD. For example, the build surface and conductors 1202 and waveguides 1204 may be oriented substantially at a build angle BA of 45 degrees.

[0089] During the continuous layering of material in a laminated fabrication process, the build surfaces 1210 and waveguides 1202 and 1204 are angled to reduce build defects and deformation during printing. When a surface is aligned with the build direction, the surface can be manufactured with minimal defects because material layers are added directly on top of each other in the build direction BD. However, when the surface of a component being manufactured is angled relative to the build direction BD, deformation can occur during the layering process in a laminated fabrication. Specifically, the lower surface facing the base 1208, such that the surface normal of a component pointing directly to the surface normal 1212 of the base 1208, can have significant manufacturing defects due to the pull of gravity. Furthermore, manufacturing defects can also originate from thermal effects in the laminated fabrication process, such as powder bed melting (PBF). In thermally laminated fabrication processes (such as PBF), plates and sections with insufficient support and lower surfaces can deform due to poor thermal energy migration within the sections. Although the features can be addressed physically, poor thermal migration caused by insufficient support can lead to component warping, which is undesirable in waveguide manufacturing and operation.

[0090] For example, unless components are provided to support the part being manufactured, the pulling force due to gravity can cause significant mechanical defects such as warping, collapse, breakage, or others when forming a surface parallel to the base 1208. These defects tend to occur at locations where one or more walls of the manufactured component encounter a significant transition in the construction direction (e.g., approaching 0° or an angle parallel to the base 1208). When the surface is oriented from perpendicular to the construction direction to nearly parallel to the construction direction BD, surface stability is improved and manufacturing defects are reduced. Therefore, it is desirable to maintain the angle between different surfaces within a specified range of 45° + / - 25° to prevent defects.

[0091] At a 45° orientation (such as build angle BA in Figure 13b), manufacturing defects are reduced and waveguides can be manufactured with higher reliability and predictability. However, depending on the shape and configuration of the component, manufacturing defects can still be prevalent at a build angle BA of 45°. For example, a filter 130 with a plate 134 containing an aperture 136 formed therein is more prone to breakage and warping due to the compromised structural integrity caused by the aperture 136. As illustrated in Figure 13a, a filter 1230 framed by a dashed line in waveguide 1202 has at least a partially downward-facing surface toward a base 1208. The downward-facing nature of filter 1230 makes it susceptible to manufacturing defects and build failures. The bridging length of filter 1230 with the aperture formed therein can cause significant distortion and lead to build failures.

[0092] To prevent deformation, a support bridge 1232 may be formed to support the filter 1230 within the channel of the waveguide 1202. This will support the generation of the critical aperture size without hindering its performance. During post-processing, mechanical removal of the bridge is not necessary. The filter 1230, support bridge 1232, and waveguide 1202 may be formed according to any of the embodiments described in this invention.

[0093] Some waveguides operating in the high-frequency range are typically small in size and can be easily manufactured using multilayer fabrication. However, larger waveguides (such as C-band waveguides) are larger and require larger multilayer fabrication equipment. Larger waveguides and fabrication equipment present unique challenges in waveguide manufacturing.

[0094] For example, a possible multilayer manufacturing process may include a powder bed melting (PBF) process that incorporates one of the commonly used printing techniques, such as direct metal laser sintering (DMLS), electron beam melting (EBM), selective thermal sintering (SHS), selective laser melting (SLM), and selective laser sintering (SLS). These PBF methods use a heating element as a printing source (such as a laser or electron beam) to melt and fuse material powder together. The process sintersulates the powder layer by layer until the entire part is completed. Similar operations can be performed using any other manufacturing method known in multilayer manufacturing. As used herein, "printing source" may mean inkjet, combined jet, extruder, laser, electron beam, printhead, or other heating device used to generate, extrude, melt, and fuse materials known in multilayer manufacturing.

[0095] In large-scale additive manufacturing systems, two or more print sources may be required to cover the entire range of components produced in the system. When using multiple print sources, each print source can print within its individual print range, and can also print within a common area shared by two or more print sources.

[0096] Figure 14 illustrates the printing range of a multilayer fabrication system with two print sources (i.e., print sources 1 and 2). Print sources 1 and 2 are operable to print two monolithic, single-material, isotropic waveguides 100 by a multilayer fabrication process. As shown, print source 1 can print on a print range 1400. Print source 2 can print on a print range 1402. In a small segment, print ranges 1400 and 1402 can overlap. This area where the print sources overlap is called a stitching region 1403. In this stitching region 1403, the printing of a single component is performed by the two print sources, and the individual prints from each print source are "stitched" together to form a single component.

[0097] Misalignment of print sources 1 and 2 can be detrimental to the fabrication of a waveguide. If print sources 1 and 2 are misaligned, or if the accuracy of one or more print sources is low, there is a risk that multiple print sources may be printed in an area where only one print source intends to form a component, resulting in undesirable excess and deformation of material on the component in the misaligned section. Alternatively, due to misalignment, all print sources may be unable to form a waveguide in a specific area of ​​the stitching region, thereby leaving undesirable gaps, voids, and openings in the waveguide walls that are intended to be closed. Furthermore, misalignment can lead to undesirable indicator lines, protrusions, and other defects that can affect the appearance and function of the waveguide. Therefore, misalignment of print sources can adversely affect the fabrication and performance of a waveguide.

[0098] Waveguide 100 may include a design intended to ensure the production of a complete waveguide without defects when manufactured in a stacking system comprising multiple print sources. For example, waveguide 100 may further include a thickened strip 124 surrounding the outer wall of the waveguide, thicker than the other walls of the waveguide. Strip 124 may be disposed in a component of waveguide 100 formed in a stitching region 1403 of a stacking manufacturing system shared by two or more print sources. In the event of print source misalignment, the thickened strip 124 of the print material ensures that the waveguides are properly stitched together, adds redundant material to complete the waveguide formation and closes any gaps or voids, and smooths any indicative lines that may be formed during stacking. Therefore, even in the event of print source misalignment, the waveguide can be reliably and consistently printed without defects.

[0099] Although the concepts described herein are referenced to C-band and other large waveguides, it should be understood that the principles, structures, and methods described herein are applicable to waveguides that propagate electromagnetic waves of any known frequency / wavelength. This invention is not intended to limit itself in any way to waveguides operating within certain ranges. In fact, this invention is applicable to other waveguides, such as S-band, X-band, or other waveguide types.

[0100] The examples illustrated in the figures are used, and specific language is used to describe these examples herein. However, it should be understood that this is not intended to limit the scope of the technology. Alternatives and further modifications to the features illustrated herein, as well as additional applications of the examples illustrated herein, will be considered within the scope of this specification.

[0101] While this invention may not explicitly disclose that some embodiments or features described herein can be combined with other embodiments or features described herein, this invention should be understood to describe any such combinations that can be practiced by a person of ordinary skill. Unless otherwise indicated herein, the use of "or" in this invention should be understood to mean non-exclusive or, i.e., "and / or".

[0102] Furthermore, the described features, structures, or characteristics can be combined in one or more instances in any suitable manner. In the foregoing description, various specific details (such as examples of various configurations) are provided to offer a thorough understanding of one instance of the described technology. However, it will be appreciated that the technology can be practiced without one or more of these specific details, or using other methods, components, devices, etc. In other instances, well-known structures or operations have not been shown or described in detail to avoid obscuring the nature of the technology.

[0103] Although the subject matter has been described in language specific to structural features and / or operation, it should be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features and operation described above. Rather, the specific features and operation described above are disclosed as examples of implementing the claims. Various modifications and alternative configurations may be devised without departing from the spirit and scope of the described technology.

[0104] 100: Waveguide 102: Channel 104: Port 105: Port 106: Port 108: Port 110: Port 112: Upper flange 114: U-shaped bend 116: U-shaped bend 118: Bend 120: Bend 122: T-connector 124: Thickening zone 126: Inner cavity 128:Outer wall 128a: Side 128b: Side 128c: Side 128d: Side 129: Inner surface 130: Filter 132: Supporting bridge 132a: First Interface 132b: Second Interface 132c: Third Interface 133: Phantom T-connector 134: Board 135: Peripheral Edge 136: Aperture 136a: Upper surface 136b: Side surface 136c: Side surface 136d: Lower surface 137: Bottom surface 138a: Transition surface 138b: Transition surface 138c: Transition surface 138d: Transition surface 140a: Surface 140b: Surface 142a: Transition surface 142b: Transition surface 932: Strip-supported bridge 932a: Interface 932b: Interface 1100: Filter Assembly 1102: Filter Assembly 1130: Filter 1132a: Support bridge 1132b: Support Bridge 1136: Filter 1136a: Upper surface 1136b: Side surface 1136c: Side surface 1136d: Lower surface 1200: Laminated Manufacturing System 1202: Waveguide 1204: Waveguide 1206: Construction board / substrate 1208: Base 1210: Constructing Surfaces 1212: Surface 1230: Filter 1232: Supporting bridge 1400: Print Range 1402: Print Range 1403: Sutured area a: First dimension BA: Construction Perspective BD: Construction Direction b: Second size C: Area c: First dimension D: Area d: First dimension g: angle h: height P: Path RW: Radio wave w: width

Claims

1. A method for fabricating a waveguide using a multilayer fabrication system, the method comprising: A construction plate is provided, comprising a base and one or more construction surfaces oriented at an angle relative to the base; Material is continuously layered on the building plate in a construction direction perpendicular to one surface of the base, wherein the continuous layering includes: forming a channel including an outer wall defining an inner cavity configured to propagate electromagnetic waves; forming a filter disposed in the inner cavity of the channel, the filter including a peripheral edge, an aperture, and a downward-facing surface of the base relative to the building plate; and forming a support bridge including a first interface connected at a first location to an inner surface of the outer wall, and a second interface connected at a location between the peripheral edge of the filter and the aperture in the filter to support the downward-facing surface of the filter within the channel.

2. The method of claim 1, wherein the stacking manufacturing system includes two or more printing sources, each printing source printing in a region shared by the two or more printing sources, wherein the method further includes forming a band around the outer wall in a stitched region of the waveguide, configured to print in the region shared by the two or more printing sources.

3. The method of claim 1, wherein the one or more building surfaces are oriented at 45 degrees relative to the base.

4. The method of claim 1 further includes forming the support bridge to remain in place during operation of the waveguide.

5. The method of claim 1, further comprising forming a plurality of support bridges including the support bridge, each including a first interface at its respective location connected to an inner surface of the outer wall, and a second interface at its respective location connected to the filter to support the filter within the channel, wherein the plurality of support bridges are offset from each other.

6. The method of request item 1, wherein the waveguide system is integral.

7. The method of claim 1, wherein the filter comprises an iris filter having the aperture formed therein via a plate, and the second interface of the support bridge is connected to the plate.

8. The method of request item 1, further including: The support bridge is configured to further include a third interface at a second location connected to one of the inner surfaces of the outer wall.

9. The method of request item 1, further comprising: A transition surface is formed between the first interface and the inner surface, and a transition surface is formed between the second interface and the filter.

10. The method of claim 8 further includes: A transition surface is formed between the third interface and the inner surface.

11. The method of claim 1, wherein the channel comprises a substantially rectangular cross-section and the outer wall comprises four sides configured as a rectangular shape.

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