Multilayer air waveguide antenna with layer-to-layer connections

Abstract

This document describes techniques, apparatus, and systems for multilayer air waveguides with layer-to-layer connections. Each preformed layer of the air waveguide is attached to at least one other preformed layer via a mechanical interface. The mechanical interface can be a stud-based interface, a snap-fit ​​fastener-based interface, a ball-and-socket-based interface, or a pressure contact interface utilizing the irregular, rough surface of each preformed layer. The mechanical interfaces of the preformed layers structurally hold the air waveguide together and electrically couple all the preformed layers. In this way, the cost of manufacturing this air waveguide antenna can be lower than previous manufacturing processes.

Description

Background Technology

[0001] Air waveguides are used in many applications, such as as antennas, to shape or filter electromagnetic energy beams based on frequency. Air-filled channels are some of the internal features of an air waveguide. These channels can include openings called radiators or slots, which allow electromagnetic energy to be filtered in or out.

[0002] Some air waveguides can be formed in layers, for example, using a substrate material stacked with solder (e.g., tin-bismuth (Sn-Bi) solder) to mechanically bond and electrically couple these layers to keep them at a common potential (e.g., grounding these layers to each other). Typically, these layers are made using injection-molded plastic (e.g., filled polyetherimide (PEI)) and have a metallic coating (e.g., silver). This method of using metal-coated plastic to form air waveguides with multiple metal coatings can be too expensive for some applications, such as automotive scenarios where mass production is expected eventually. Summary of the Invention

[0003] This document describes techniques, apparatus, and systems relating to multilayer air waveguide antennas with layer-to-layer connections. Each preformed layer of the air waveguide antenna is attached to at least one other preformed layer via a mechanical interface. The mechanical interface can be a stud-based interface, a snap-fit ​​fastener-based interface, a ball-and-socket-based interface, or a pressure contact interface utilizing the irregular, rough surface of each preformed layer. The mechanical interfaces of the preformed layers structurally hold the air waveguide antenna together and electrically couple all the preformed layers. In this way, the cost of manufacturing this air waveguide antenna can be lower than previous manufacturing processes.

[0004] The aspects described below include a multilayer air waveguide antenna with layer-to-layer connections, configured to guide electromagnetic energy through one or more channels including conducting surfaces. At least one pre-formed layer from the plurality of layers of the air waveguide antenna includes at least one interface surface with a mechanical interface, which serves as a layer-to-layer connection between at least two of the plurality of layers and is configured to provide structural support and a common electrical ground.

[0005] This document also describes methods performed by the techniques, apparatus and systems summarized above, and other methods set forth herein, as well as apparatus for performing these methods.

[0006] This invention provides a simplified concept related to multilayer air waveguide antennas with layer-to-layer connections, which is further described in the detailed description and accompanying drawings. This invention is not intended to identify essential features of the claimed subject matter, nor is it intended to define the scope of the claimed subject matter.

[0007] Brief description of the attached figures

[0008] The following figures illustrate details of one or more aspects of a multilayer air waveguide antenna with layer-to-layer connections. Throughout the figures, the same numbers are generally used to refer to similar features and components:

[0009] Figure 1 An example environment is shown where a multilayer air waveguide antenna with layer-to-layer connections can be used on a vehicle;

[0010] Figures 2-1 to 2-4 An example layer implementation of a multilayer air waveguide antenna with layer-to-layer connections is shown;

[0011] Figures 3-1 to 3-3 Three example preformed layers of a multilayer air waveguide antenna with layer-to-layer connections are shown;

[0012] Figure 4 An example assembly is shown, including a multilayer air waveguide antenna with layer-to-layer connections, which is held together under pressure against the radome.

[0013] Figures 5-1 to 5-2 An example interlocking protrusion mechanical interface with a multilayer air waveguide having layer-to-layer connections is shown;

[0014] Figures 6-1 to 6-2 An example snap-fit ​​fastener mechanical interface with a multilayer air waveguide having layer-to-layer connections is shown;

[0015] Figures 7-1 to 7-2 An example of a ball-and-socket mechanical interface including multilayer air waveguides with layer-to-layer connections is shown;

[0016] Figure 8 An example of an irregular, rough surface is shown as the mechanical interface of a multilayer air waveguide with layer-to-layer connections; and

[0017] Figure 9 An example method for fabricating a multilayer air waveguide with layer-to-layer connections is shown. Detailed Implementation

[0018] Overview

[0019] Radar systems are a sensing technology that some automotive systems rely on to acquire information about their surroundings. Radar systems typically use antennas or waveguides to guide transmitted or received electromagnetic energy or signals. Such radar systems can use any combination of antennas and waveguides to provide increased gain and directivity. As the automotive industry increasingly uses radar systems in more vehicles, reducing the costs associated with the waveguides used in these radar systems has become a higher priority for manufacturers.

[0020] This document describes a multilayer air waveguide antenna with layer-to-layer connections. This air waveguide is significantly cheaper to manufacture than existing air waveguide technologies. An example air waveguide antenna can be fabricated by stacking multiple pre-formed layers, held together by a mechanical interface between two adjacent surfaces of two layers. This mechanical interface can be a series of cylindrical protrusions on each layer; when these layers are pressed together, the cylindrical protrusions securely connect the layers to each other, much like a child's toy blocks. Alternatively, the mechanical interface can be a series of snap fasteners, ball joints, or an area of ​​rough surface held together by mechanical force under compression. Furthermore, the mechanical interface provides electrical functionality; it electrically couples the multiple layers to a common potential, thereby eliminating the need for solder. Because there is no need for solder, there is no risk of thermal damage to the metal-coated plastic when assembling multiple layers together, resulting in fewer manufacturing steps and lower manufacturing costs. Therefore, the example air waveguide is significantly simpler and cheaper to manufacture than existing waveguide technologies.

[0021] Example Environment

[0022] Figure 1 An example environment 100 is shown, in which a radar system 102 with multiple layers 104 of air waveguide antennas 106 (with layer-to-layer connections 108) is used on a vehicle 110. The vehicle 110 can use one or more waveguide antennas 106 to enable the operation of the radar system 102, which is configured to determine the proximity, angle, or speed of one or more objects 112 in the vicinity of the vehicle 110.

[0023] At least one or more layers may form one or more channels 114 and one or more openings 116 on the air waveguide antenna 106. A layer may form only channels 114 or only openings 116, or the layer may form any combination of channels 114 and openings 116. Openings 116 allow electromagnetic energy to enter (e.g., ports) and exit (e.g., slots) the channels 114. Typically, the channels 114 will have port openings at one end and slot openings at the other end. Channels 114 and openings 116 manipulate electromagnetic energy in a manner advantageous to the specific application of the air waveguide antenna.

[0024] Although shown as a car, vehicle 110 can represent other types of motorized vehicles (e.g., motorcycles, buses, tractors, semi-trailers, or construction equipment), non-motorized vehicles (e.g., bicycles), rail vehicles (e.g., trains or trams), water vehicles (e.g., boats or ships), aircraft (e.g., airplanes or helicopters), or spacecraft (e.g., satellites). Typically, manufacturers can mount radar system 102 onto any mobile platform, including mobile machinery or robotic equipment. In other implementations, other devices (e.g., desktop computers, tablets, laptops, televisions, computing watches, smartphones, gaming systems, etc.) can combine radar system 102 with air waveguide antenna 106 and support the techniques described herein.

[0025] In the depicted environment 100, a radar system 102 is mounted near or integrated within the front of a vehicle 110 to detect an object 112 and avoid collisions. The radar system 102 provides a field of view 118 directed toward one or more objects 112. The radar system 102 can project the field of view 118 from any external surface of the vehicle 110. For example, a vehicle manufacturer may integrate the radar system 102 into a bumper, side mirror, headlight, taillight, or any other internal or external location where the object 112 needs to be detected. In some cases, the vehicle 110 includes multiple radar systems 102, such as a first radar system 102 and a second radar system 102 providing a larger field of view 118. Typically, a vehicle manufacturer may design the location of one or more radar systems 102 to provide a specific field of view 118 encompassing an area of ​​interest, including, for example, in or around a driving lane aligned with the vehicle's path.

[0026] Radar system 102 may be part of vehicle 110. Vehicle 110 may also include at least one vehicle system that relies on data from radar system 102, including a driver assistance system, an autonomous driving system, or a semi-autonomous driving system. Radar system 102 may include an interface to the vehicle system. Radar system 102 may output signals via the interface based on electromagnetic energy received by radar system 102.

[0027] Typically, automotive systems use radar data provided by radar system 102 to perform functions. For example, a driver assistance system may provide blind spot monitoring and generate a warning indicating a potential collision with object 112 detected by radar system 102. In this case, radar data from radar system 102 indicates when changing lanes is safe or unsafe. An autonomous driving system may move vehicle 110 to a specific location on the road while avoiding a collision with object 112 detected by radar system 102. The radar data provided by radar system 102 can provide information about the distance to and position of object 112, enabling the autonomous driving system to perform emergency braking, lane changes, or adjust the speed of vehicle 110.

[0028] Radar system 102 typically includes a transmitter (not shown) and at least one antenna, including an air waveguide antenna 106, for transmitting electromagnetic signals. Radar system 102 typically includes a receiver (not shown) and at least one antenna, including an air waveguide antenna 106, for receiving reflected versions of these electromagnetic signals. The transmitter includes components for transmitting electromagnetic signals. The receiver includes components for detecting reflected electromagnetic signals. The transmitter and receiver may be integrated together on the same integrated circuit (e.g., a transceiver integrated circuit) or separately on different integrated circuits.

[0029] The radar system 102 also includes one or more processors (not shown) and a computer-readable storage medium (CRM) (not shown). The processor may be a microprocessor or a system-on-a-chip. The processor executes instructions stored in the CRM. For example, the processor may control the operation of the transmitter. The processor may also process electromagnetic energy received by the antenna and determine the position of the object 112 relative to the radar system 102. The processor may also generate radar data for vehicle systems. For example, the processor may control an autonomous or semi-autonomous driving system of the vehicle 110 based on processed electromagnetic energy from the antenna.

[0030] Although depicted as three layers (e.g., layers 104-1, 104-2, and 104-3), an air waveguide antenna may include at least two or more layers 104. These layers can be any solid material, including wood, carbon fiber, glass fiber, metal, plastic, or combinations thereof. The air waveguide antenna 106 may also include a printed circuit board (PCB). A common material for layers 104 is injection-molded plastic (e.g., filled PEI). Each layer 104 may be metallized (e.g., coated via electroplating, physical vapor deposition, painting, or other forms of metallization). The metal used to metallize layers 104 can be silver, silver alloys, copper, aluminum, cold-rolled steel, stainless steel, or other conductive metals.

[0031] On at least one or more surfaces of each layer 104, the layers 104 are engaged with each other via layer-to-layer connections 108 (referred to as mechanical interfaces 108). The mechanical interfaces 108 may be a series of cylindrical protrusions on each layer, a series of snap fasteners, ball sockets, areas compressed against each other's rough surfaces, or other forms of mechanical interfaces that structurally and electrically connect the layers 104 to each other.

[0032] The details of the mechanical interface 108 are described below with reference to the accompanying drawings. Typically, the mechanical interface 108 enables a cost-effective manufacturing process for the air waveguide antenna 106 without the need for solder to physically connect and electrically couple the layers 104 to each other. Using the relatively inexpensive air waveguide antenna 106 for radar applications in the vehicle 110 can ultimately contribute to a lower price for the vehicle 110 offered to the customer.

[0033] Example air waveguide antenna

[0034] Figures 2-1 to 2-4 An example layer implementation of a multilayer air waveguide antenna 200 with layer-to-layer connections is shown. Figure 2-1 In this diagram, layer 200-1 represents the first layer of the air waveguide antenna 200, and layer 200-n represents the nth layer of the air waveguide antenna, where n is an integer greater than one. Each layer from 200-1 to 200-n has at least one interface surface, which includes a mechanical interface. Figures 5-1 to 8Some examples of mechanical interfaces are described. A first interface surface of the first layer will have a mechanical interface complementary to a second interface surface of the second layer adjacent to the first layer. For example, if the mechanical interface utilized includes a ball-and-socket type interface, the first interface surface may include “balls,” while the second interface surface may include “sockets.” Alternatively, the first and second interface surfaces may include a combination of “balls” and “sockets,” provided that each “ball” on one interface surface is aligned with a “socket” on the other interface surface. This is true regardless of the type of interface used, unless, in this implementation, the mechanical interfaces on the two interface surfaces are irregular, rough regions. In this implementation, the irregular nature of the rough surfaces, and the nature of the layers being compressed together, results in a complementary relationship between the two adjacent interface surfaces.

[0035] Figure 2-2 A two-layer implementation of the air waveguide antenna 200 is shown (e.g., layer 202 and layer 204). One or both of layers 202 and 204 can form a channel, an opening, or a combination of a channel and an opening. Figure 2-3 A multi-layer implementation of the air waveguide antenna 200 is shown. This multi-layer implementation is similar in range to... Figure 2-2 The implementation, in addition to one or more inner layers 206, may include layers adjacent to two other layers. One or more inner layers 206 may have two interface surfaces, each of which has a mechanical interface. The mechanical interface on the interface surface may be a complementary interface of one type of mechanical interface, a combination of complementary interfaces of one type of mechanical interface, or any combination thereof, and includes other types of mechanical interfaces. Furthermore, as... Figure 2-4 As shown, interface surfaces 208-1 and 208-2 of inner layer 208 may both include the same complementary interface shape, or as shown in inner layer 210, one interface surface 210-1 may include one mechanical interface, while the other interface surface 210-2 may include another mechanical interface. The mechanical interface used on any interface surface of any layer of the air waveguide antenna 200 engages with the complementary mechanical interface of any adjacent interface surface.

[0036] Figures 3-1 to 3-3 Three example preformed layers 300 of a multilayer air waveguide antenna with layer-to-layer connections are illustrated, along with the relationship between one or more openings 302 (e.g., ports 302), one or more channels 304, and one or more openings 306 (e.g., slots 306) included in the preformed layers. In a non-limiting example, the preformed layers 300 comprise PEI and are preformed by an injection molding process. The preformed layers 300 are coated with a conductive metal that electrically couples or grounds the preformed layers 300 to each other once they are assembled together.

[0037] Preformed layer 300-1 includes one or more ports 302. The outer surface 308 of the air waveguide antenna may not include the mechanical interface as described herein. An interface surface of preformed layer 300-1, on the side of preformed layer opposite to surface 308 and not shown, may include a mechanical interface that engages with a mechanical interface 310 on interface surface 312 of preformed layer 300-2. Preformed layer 300-2 includes one or more channels 304. Preformed layer 300-2 further includes a second interface surface (opposite to interface surface 312 and not shown), which may include a mechanical interface that engages with interface surface (not shown) of preformed layer 300-3. Preformed layer 300-3 includes one or more slots 306 and an outer surface 314. The outer surface 314 is opposite to the interface surface (not shown) of preformed layer 300-3 and may not include a mechanical interface, similar to the outer surface 308 of preformed layer 300-1.

[0038] Figure 3-2 The relationship between one or more ports 302 of preforming layer 300-1, one or more channels 304 of preforming layer 300-2, and one or more slots 306 of preforming layer 300-3 is illustrated. One or more ports 302 allow electromagnetic energy to enter the air waveguide antenna, traverse one or more channels 304, and exit from one or more slots 306.

[0039] Figure 3-3 A cross-sectional view of preforming layers 300-1, 300-2, and 300-3 after they have been interlocked is shown. Channel 304 of preforming layer 300-2 feeds into slot 306 of preforming layer 300-3. Port 302 of preforming layer 300-1 is not shown, but in the cross-sectional view it can be presented as resembling slot 306 and opening through preforming layer 300-1.

[0040] Figure 4 An example assembly 400 is shown, comprising a multilayer air waveguide antenna 402 with layer-to-layer connections, the air waveguide antenna 402 being held together under pressure against a radome 404. The air waveguide antenna 402 is held together under pressure against the radome 404 by one or more support beams 406. The support beams 406 may extend or partially extend from the radome 404, through the air waveguide antenna 402, to a radar control module PCB (RCM-PCB) 408. The support beams 406 may be joined to the housing enclosing the air waveguide antenna 402 and the radome 404 by plastic laser welding, adhesives, or some other bonding process. The support beams 406 compress the radome, the multiple layers of the air waveguide antenna, and the RCM-PCB 408. This compression keeps the assembly 400 under pressure and ensures structural integrity and proper grounding throughout the assembly 400.

[0041] RCM-PCB 408 may include a monolithic microwave integrated circuit 410 (MMIC 410). In one example, electromagnetic energy derived from the MMIC 410 passes through one or more ports 412 (similar to...). Figure 3-1 The port 302) enters the air waveguide antenna 402, traversing one or more channels 414 (similar to...). Figure 3-1 Channel 304), and from one or more slots 416 (similar to Figure 3-1 (306) left.

[0042] The assembly 400, which includes a multilayer air waveguide antenna 402 with layer-to-layer connections held together by pressure against the radome 404, can be an inexpensive option for manufacturers to use in radar systems. Solder, which typically requires manufacturing materials with higher heat ratings, is not used to physically and electrically hold the multiple layers of the air waveguide antenna 402 together, and these layers can be manufactured using cheaper materials (e.g., materials with lower heat ratings).

[0043] Example mechanical interface

[0044] Figures 5-1 to 5-2 An example interlocking protrusion mechanical interface for a multilayer air waveguide antenna with layer-to-layer connections is shown. Figure 5-1 In the middle, one or more closed cylindrical protrusions 500-1 with a circular cross-section 500-2 extend from the interface surface 502. Figure 5-2 In the interface, one or more open cylindrical protrusions 504-1 having a circular cross-section 504-2 extend from the interface surface 506. The circular cross-section 500-2 of the closed cylindrical protrusion 500 is configured to engage with the circular cross-section 504-2 of the open cylindrical protrusion 504 at multiple locations 508.

[0045] Figures 6-1 to 6-2 An example snap-fit ​​fastener mechanical interface for a multilayer air waveguide antenna with layer-to-layer connections is shown. Figure 6-1 In the interface, an interlocking protrusion having a closed cylindrical shape 600 has a lip 602 around the outer wall of the closed cylindrical shape 600, and the interlocking protrusion extends from the interface surface 604. An interlocking protrusion having an open cylindrical shape 606 has a groove 608 around the inner wall of the open cylindrical shape 606, and the interlocking protrusion extends from the interface surface 610. Figure 6-2 In the middle, interface surface 604 and interface surface 610 are pressed together so that the lip 602 of the closed cylindrical shape 600 engages and rests in the groove 608 of the open cylindrical shape 606.

[0046] Figures 7-1 to 7-2 An example of a sphere-and-socket mechanical interface including a multilayer air waveguide antenna with layer-to-layer connections is shown. Figure 7-1 In this configuration, a spherical shape 700 extends from the interface surface 702, and a spherical cavity 704 is located within the interface surface 706. For example... Figure 7-2 As shown, interface surface 702 and interface surface 706 are pressed together, and the spherical shape 700 extending from interface surface 702 can engage with the spherical cavity in interface surface 706.

[0047] Figure 8 An example of an irregularly rough surface mechanical interface for a multilayer air waveguide antenna 800 with layer-to-layer connections is shown. Figure 8 In the exploded view of the multiple preformed layers 802 of the air waveguide antenna 800, an irregular rough surface 804 of the preformed layer 802 is revealed, which faces other irregular rough surfaces 804 of adjacent preformed layers 802. A magnified view 806 of the irregular rough surface 804 shows an example irregular pattern that the rough surface can have. Other irregular patterns may also be used. Furthermore, the irregular rough surface 804 can be created by a mold used to form the preformed layer 802, by a stamping tool, or by other processes.

[0048] The example mechanical interface described herein securely fastens two or more preformed layers of a multilayer air waveguide antenna with layer-to-layer connections to each other. Similarly, this example mechanical interface electrically couples several preformed layers and can provide an inexpensive process for manufacturing air waveguide antennas.

[0049] Example Method

[0050] Figure 9 An example method for manufacturing a multilayer air waveguide with layer-to-layer connections is shown. At 902, these layers of the air waveguide antenna are formed using an injection molding process. The plastic can have lower thermal power because it is not affected by welding. At 904, these layers are coated with a metal. The coating process can include plating, physical vapor deposition, painting, or another coating process. The metal used to coat these layers can include silver, silver alloys, copper, gold, steel, or other conductive metals. Similarly, other conductive materials can be used to coat these layers. At 906, the layers are pressed together until the mechanical interfaces on each interface surface of these layers engage with the mechanical interfaces on the adjacent layers. At 908, the air waveguide antenna is joined against the radome. Through this joining process, the layers are held together under pressure against the radome.

[0051] Eliminating the use of welding techniques to form metal-coated plastic air waveguides can greatly simplify waveguide manufacturing processes; when mechanical interfaces can be used instead of solder, there is virtually no risk of thermal damage. This document describes techniques, apparatus, and systems relating to multilayer air waveguide antennas with layer-to-layer connections. Using the techniques, apparatus, and systems described herein can significantly reduce manufacturing costs associated with radar systems used in the automotive industry.

[0052] Additional examples

[0053] Example 1: An apparatus comprising: an air waveguide antenna having layer-to-layer connections between multiple layers, the air waveguide antenna being configured to guide electromagnetic energy through one or more channels, the channels including conductive surfaces; at least one preformed layer from the multiple layers of the air waveguide, the preformed layer including at least one interface surface having a mechanical interface configured as a layer-to-layer connection between at least two of the multiple layers to provide structural support and a common electrical ground.

[0054] Example 2: The apparatus of Example 1, wherein at least one preformed layer comprises: a core layer comprising a plastic material; and an outer layer comprising a metallic material.

[0055] Example 3: The device of any of the preceding examples, wherein the outer layer comprises at least one of silver or a silver alloy.

[0056] Example 4: An apparatus of any of the preceding examples, wherein the mechanical interface comprises a series of interlocking protrusions extending from at least one surface of at least one or more preformed layers, the interlocking protrusions being arranged to engage with protrusions from adjacent preformed layers of the plurality of layers.

[0057] Example 5: An apparatus of any of the preceding examples, wherein: the interlocking protrusion extending from a first surface of a first preformed layer comprises a closed cylindrical shape; the interlocking protrusion extending from a second surface of a second preformed layer comprises an open cylindrical shape having a cylindrical cavity; and a plurality of circular cross sections of the interlocking protrusion extend from the first surface of the first preformed layer, and the plurality of circular cross sections are configured to engage with at least one or more circular cross sections of the interlocking protrusion extending from a second surface of a second preformed layer adjacent to the first preformed layer.

[0058] Example 6: An apparatus of any of the preceding examples, wherein: the interlocking protrusion extending from a first surface of a first preform layer includes a closed cylindrical shape having a lip surrounding an outer wall of the closed cylindrical shape; the interlocking protrusion extending from a second surface of a second preform layer includes an open cylindrical shape having a cylindrical cavity having a groove surrounding an inner wall of the cylindrical cavity; and the lip of the interlocking protrusion extending from the first surface of the first preform layer is configured to engage with a groove of the interlocking protrusion extending from a second surface of a second preform layer adjacent to the first preform layer.

[0059] Example 7: An apparatus of any of the preceding examples, wherein: the mechanical interface of the first surface of the first preform layer includes a series of spherical shapes extending from the first surface; the mechanical interface of the second surface of the second preform layer includes a series of spherical cavities in the second surface; and the spherical shapes extending from the first surface of the first preform layer engage with the spherical cavities in the second surface of the second preform layer adjacent to the first preform layer.

[0060] Example 8: An apparatus of any of the preceding examples, wherein: each of the mechanical interface of the first surface of the first preformed layer and the mechanical interface of the second surface of the second preformed layer includes: an irregular rough surface finish in the region to be joined of both the first surface and the second surface; and the irregular rough surface finish of the first surface of the first preformed layer joins with an irregular rough surface finish of the second surface of the second preformed layer adjacent to the first preformed layer.

[0061] Example 9: An apparatus of any of the preceding examples, wherein the preformed layers are held together under pressure against the radome.

[0062] Example 10: A system comprising: an apparatus configured to transmit or receive electromagnetic signals; and an air waveguide antenna having layer-to-layer connections between multiple layers, the air waveguide antenna being configured to guide electromagnetic energy through one or more channels, the channels including conductive surfaces, at least one preformed layer from the multiple layers of the air waveguide, the preformed layer including at least one interface surface having a mechanical interface configured as a layer-to-layer connection between at least two of the multiple layers to provide structural support and a common electrical ground.

[0063] Example 11: A system of any of the preceding examples, wherein at least one preformed layer comprises: a core layer comprising a plastic material; and an outer layer comprising a metallic material.

[0064] Example 12: A system of any of the preceding examples, wherein the outer layer comprises at least one of silver or a silver alloy.

[0065] Example 13: A system of any of the preceding examples, wherein the mechanical interface comprises a series of interlocking protrusions extending from at least one surface of at least one or more preformed layers, the interlocking protrusions being arranged to engage with protrusions from adjacent preformed layers of the plurality of layers.

[0066] Example 14: A system of any of the preceding examples, wherein: the interlocking protrusion extending from a first surface of a first preform layer comprises a closed cylindrical shape; the interlocking protrusion extending from a second surface of a second preform layer comprises an open cylindrical shape having a cylindrical cavity; and a plurality of circular cross sections of the interlocking protrusion extend from the first surface of the first preform layer, and the plurality of circular cross sections are configured to: engage with at least one or more circular cross sections of the interlocking protrusion extending from a second surface of a second preform layer adjacent to the first preform layer.

[0067] Example 15: A system of any of the preceding examples, wherein: an interlocking protrusion extending from a first surface of a first preform layer includes a closed cylindrical shape having a lip surrounding an outer wall of the closed cylindrical shape; an interlocking protrusion extending from a second surface of a second preform layer includes an open cylindrical shape having a cylindrical cavity having a groove surrounding an inner wall of the cylindrical cavity; and the lip of the interlocking protrusion extending from the first surface of the first preform layer is configured to engage with a groove of the interlocking protrusion extending from a second surface of a second preform layer adjacent to the first preform layer.

[0068] Example 16: A system of any of the preceding examples, wherein: the mechanical interface of the first surface of the first preform layer includes a series of spherical shapes extending from the first surface; the mechanical interface of the second surface of the second preform layer includes a series of spherical cavities in the second surface; and the spherical shapes extending from the first surface of the first preform layer engage with the spherical cavities in the second surface of the second preform layer adjacent to the first preform layer.

[0069] Example 17: A system of any of the preceding examples, wherein: each of the mechanical interface of the first surface of the first preformed layer and the mechanical interface of the second surface of the second preformed layer includes: an irregular rough surface treatment in the region to be joined of both the first and second surfaces; and the irregular rough surface treatment of the first surface of the first preformed layer joins with an irregular rough surface treatment of the second surface of the second preformed layer adjacent to the first preformed layer.

[0070] Example 18: A system of any of the preceding examples, wherein the preformed layers are held together under pressure against the radome.

[0071] Example 19: A system of any of the preceding examples, wherein the equipment includes a radar system.

[0072] Example 20: A system of any of the preceding examples, where the system is a means of transportation.

[0073] Conclusion

[0074] While various embodiments of the present disclosure have been described in the foregoing description and illustrated in the accompanying drawings, it should be understood that the present disclosure is not limited thereto, but can be practiced in various ways within the scope of the following claims. It will be apparent from the foregoing description that various modifications can be made without departing from the scope of the present disclosure as defined by the appended claims.

Claims

1. A waveguide apparatus, the waveguide apparatus comprising: an air waveguide antenna having layer-to-layer connections between a plurality of layers, the air waveguide antenna configured to guide electromagnetic energy through one or more channels, the channels including a conductive surface; at least one preformed layer from the plurality of layers of the air waveguide antenna, the preformed layer including at least one interface surface having a mechanical interface configured to provide structural support and common electrical ground as a layer-to-layer connection between at least two layers of the plurality of layers, wherein the plurality of layers are held together under pressure against a radome by one or more support beams.

2. The waveguide device of claim 1, wherein, the at least one preformed layer including: a core layer including a plastic material; and an outer layer including a metallic material.

3. The waveguide device of claim 2, wherein, the outer layer including at least one of silver or a silver alloy.

4. The waveguide device of claim 1, wherein, the mechanical interface including a series of interlockable protrusions extending from the at least one interface surface of the at least one preformed layer, the interlockable protrusions arranged to engage with protrusions from an adjacent preformed layer of the plurality of layers.

5. The waveguide apparatus of claim 4, wherein: the interlockable protrusions extending from a first surface of a first preformed layer include a closed cylindrical shape; the interlockable protrusions extending from a second surface of a second preformed layer include an open cylindrical shape having a cylindrical cavity; and a plurality of circular cross-sections of the interlockable protrusions extend from the first surface of the first preformed layer and are configured to engage with at least one or more circular cross-sections of the interlockable protrusions extending from the second surface of the second preformed layer adjacent to the first preformed layer.

6. The waveguide apparatus of claim 4, wherein: the interlockable protrusions extending from a first surface of a first preformed layer include a closed cylindrical shape having a lip around an outer wall of the closed cylindrical shape; the interlockable protrusions extending from a second surface of a second preformed layer include an open cylindrical shape having a cylindrical cavity having a groove around an inner wall of the cylindrical cavity; and the lip of the interlockable protrusions extending from the first surface of the first preformed layer is configured to engage with the groove of the interlockable protrusions extending from the second surface of the second preformed layer adjacent to the first preformed layer.

7. The waveguide apparatus of claim 1, wherein: the mechanical interface of a first surface of a first preformed layer includes a series of spherical shapes extending from the first surface; the mechanical interface of a second surface of a second preformed layer includes a series of spherical cavities in the second surface; and the spherical shapes extending from the first surface of the first preformed layer engage with the spherical cavities in the second surface of the second preformed layer adjacent to the first preformed layer.

8. The waveguide apparatus of claim 1, wherein: Each of the mechanical interface of the first surface of the first pre-formed layer and the mechanical interface of the second surface of the second pre-formed layer comprises: an irregular rough surface treatment in the area of both the first surface and the second surface to be joined; and The irregular rough surface treatment of the first surface of the first pre-formed layer is joined with the irregular rough surface treatment of the second surface of the second pre-formed layer adjacent to the first pre-formed layer.

9. The waveguide device of claim 1, wherein, The support beam is joined to a housing enclosing the air waveguide antenna and the radome.

10. A vehicle, the vehicle comprising: a device configured for transmitting or receiving electromagnetic signals; and an air waveguide antenna having layer-to-layer connections between a plurality of layers, the air waveguide antenna configured for guiding electromagnetic energy through one or more channels, the channels comprising a conducting surface; at least one pre-formed layer from the plurality of layers of the air waveguide antenna, the pre-formed layer comprising at least one interface surface having a mechanical interface configured for providing structural support and common electrical ground as a layer-to-layer connection between at least two layers of the plurality of layers, wherein the plurality of layers are held together under pressure against a radome by one or more support beams.

11. The vehicle of claim 10, wherein, The at least one pre-formed layer comprises: a core layer comprising a plastic material; and an outer layer comprising a metallic material.

12. The vehicle of claim 11, wherein, The outer layer comprises at least one of silver or a silver alloy.

13. The vehicle of claim 10, wherein, The mechanical interface comprises a series of interlockable protrusions extending from at least one surface of the at least one pre-formed layer, the interlockable protrusions arranged to engage with protrusions from an adjacent pre-formed layer of the plurality of layers.

14. The vehicle of claim 13, wherein: The interlockable protrusions extending from a first surface of a first pre-formed layer comprise a closed cylindrical shape; The interlockable protrusions extending from a second surface of a second pre-formed layer comprise an open cylindrical shape having a cylindrical cavity; and A plurality of circular cross-sections of the interlockable protrusions extend from the first surface of the first pre-formed layer and are configured to engage with at least one or more circular cross-sections of the interlockable protrusions extending from the second surface of the second pre-formed layer adjacent to the first pre-formed layer.

15. The vehicle of claim 13, wherein: The interlockable protrusions extending from a first surface of a first pre-formed layer comprise a closed cylindrical shape having a lip surrounding an outer wall of the closed cylindrical shape; The interlockable protrusions extending from a second surface of a second pre-formed layer comprise an open cylindrical shape having a cylindrical cavity having a groove surrounding an inner wall of the cylindrical cavity; and The lip of the interlockable protrusions extending from the first surface of the first pre-formed layer is configured to engage with the groove of the interlockable protrusions extending from the second surface of the second pre-formed layer adjacent to the first pre-formed layer. ​ 16. The vehicle of claim 10, wherein: the mechanical interface of the first surface of the first preformed layer comprises a series of spherical shapes extending from the first surface; the mechanical interface of the second surface of the second preformed layer comprises a series of spherical cavities in the second surface; and the spherical shapes extending from the first surface of the first preformed layer engage the spherical cavities in the second surface of the second preformed layer adjacent to the first preformed layer.

17. The vehicle of claim 10, wherein: each of the mechanical interface of the first surface of the first preformed layer and the mechanical interface of the second surface of the second preformed layer comprises: an irregular rough surface treatment in the area of the first surface and the second surface to be engaged; and the irregular rough surface treatment of the first surface of the first preformed layer engages the irregular rough surface treatment of the second surface of the second preformed layer adjacent to the first preformed layer.

18. The vehicle of claim 10, wherein, the support beam is engaged to a housing enclosing the air waveguide antenna and the radome.

19. The vehicle of claim 10, wherein, the device comprises a radar system.

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