Two-part folded waveguide with horn

Abstract

This document describes a two-part folded waveguide with a horn. For example, the waveguide includes a channel with an opening at one end in a longitudinal direction, and a sinusoidal shape folded back and forth around a longitudinal axis that travels through the channel in the longitudinal direction. One part of the waveguide defines a surface of the channel that features a plurality of radiating slots in a horn shape that allows the two parts of the waveguide to be arranged and configured as one assembly. The first part of the waveguide has the slots and an upper half of the channel wall, and the second part provides a lower half of the channel wall and the surface of the channel opposite the slots. Using a horn in conjunction with the two parts makes it easy to manufacture a waveguide with an internal channel that has a folded or sinusoidal shape.

Description

[0001] This application is a divisional application of the invention patent application filed on May 7, 2022, with national application number 202210492633.3, entitled "Two-part folded waveguide with horn". Background Technology

[0002] Some devices (such as radar) use electromagnetic signals to detect and track objects. One or more antennas are used to transmit and receive these electromagnetic signals. Antennas can be characterized by gain, beamwidth, or more specifically by antenna patterns, which are measures of antenna gain as a function of direction. Specific applications can benefit from precise control of the antenna pattern. Folded waveguides are millimeter-sized components that can be used to improve desired antenna characteristics; gradient lobes can be reduced or eliminated by allowing unwanted electromagnetic radiation to leak from a folded or sinusoidal channel (e.g., filled with air or other dielectrics) embedded in a small component. Forming small waveguides with complex internal channel structures can be too difficult and therefore too expensive to produce at the cost and scale (e.g., millions of units) required by industries that need to improve antenna characteristics, including automotive and communications technologies. Summary of the Invention

[0003] This document describes techniques, systems, apparatus, and methods for utilizing a two-part folded waveguide with a horn. In one example, the apparatus includes a two-part folded waveguide with a horn, which may be an air waveguide (referred to as a waveguide in this document). Due to the horn structure on the multiple radiating slots of the waveguide, a conductive bonding layer, such as a dielectric paste, is not required to fix the two parts of the waveguide during fabrication. The horn structure allows for the use of alternative methods to fix the first part of the waveguide to the second part. The described waveguide includes a channel with a rectangular opening formed at one end along a longitudinal axis, and a sinusoidal shape folded back and forth around the longitudinal axis, which runs along the channel in the longitudinal direction. The channel further forms multiple radiating slots in a horn shape, each slot including a hole through one of a plurality of surfaces defining the channel of the two-part folded waveguide. The first part of the waveguide is separated from the second part of the waveguide by a material layer.

[0004] In another example, a method for manufacturing a two-part folded waveguide with a horn is described according to the technology, system, apparatus, and method of this disclosure. The method includes: forming two parts of the two-part folded waveguide with a horn, aligning the two parts of the two-part folded waveguide with a horn, and fixing the two parts of the two-part folded waveguide with a horn. The two parts of the two-part folded waveguide with a horn can be formed by stamping, etching, cutting, machining, casting, molding, or injection molding. The two parts of the two-part folded waveguide with a horn can be fixed by plastic fasteners, metal fasteners, or double-sided adhesive.

[0005] This invention provides a simplified concept related to a two-part folded waveguide with a horn, which is further described in detail in the specific embodiments and accompanying drawings. Furthermore, systems, other technologies, systems, apparatuses, and methods are described below. 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.

[0006] Brief description of the attached figures

[0007] The details of the two-part folded waveguide with a horn are described in this document with reference to the following figures:

[0008] Figure 1 An example environment for a two-part folded waveguide with a horn, according to the present disclosure, is shown.

[0009] Figure 2-1 A top view of a two-part folded waveguide with a horn, as exemplified by this disclosure, is shown.

[0010] Figure 2-2 A top view of a two-part folded waveguide with a horn, according to another example of this disclosure, is shown;

[0011] Figure 2-3 A side view of a two-part folded waveguide with a horn, as exemplified by this disclosure, is shown.

[0012] Figure 3 The method of folding two parts of a horn-equipped waveguide for a fixed example is shown according to the present disclosure;

[0013] Figure 4 Different shapes of horns and their respective radiating slots are shown according to this disclosure;

[0014] Figure 5 An example process for forming a two-part folded waveguide with a horn, according to the present disclosure, is described;

[0015] Figure 6 A diagram illustrating the characteristics of an antenna according to this disclosure is shown; and

[0016] Figure 7 Another diagram illustrating the characteristics of the antenna according to this disclosure is shown.

[0017] The same numbers are often used throughout the accompanying drawings to refer to similar features and parts. Detailed Implementation

[0018] Overview

[0019] Some devices (such as radar) use electromagnetic signals to detect and track objects. One or more antennas are used to transmit and receive these electromagnetic signals. Antennas can be characterized by gain, beamwidth, or more specifically by antenna patterns, which are measures of antenna gain as a function of direction. Specific applications can benefit from precise control of the antenna pattern. Folded waveguides are millimeter-sized components that can be used to improve some antenna characteristics; gradient lobes can be reduced or eliminated by allowing unwanted electromagnetic energy to leak from folded or sinusoidal channels (e.g., filled with air) embedded in small components. Forming small waveguides with internally folded channels can be too difficult and therefore too expensive to manufacture at the cost and scale (e.g., millions of units) required to support some industries, including automotive and communications technology.

[0020] In contrast, this document describes a two-part folded waveguide with a horn. For example, the device includes a two-part folded waveguide with multiple surfaces defining a channel. The two-part folded waveguide includes a first portion of the waveguide having a first surface from the multiple surfaces, the first surface having a sinusoidal shape folded back and forth about a longitudinal axis that travels through the channel in a longitudinal direction. The waveguide also has multiple radiating slots. Each radiating slot is horn-shaped, the horn forming an aperture through the first surface and into the channel. At least one second surface from the multiple surfaces is part of the first portion and perpendicular to the first surface to define an upper half of a wall of the channel perpendicular to the first surface. The first portion further includes a first feature at one end of the waveguide, the first feature defining a portion of a rectangular opening in the longitudinal direction leading to the channel. A second portion of the waveguide is arranged adjacent to and parallel to the first portion, wherein a third surface from the multiple surfaces is parallel to the first surface and has the same sinusoidal shape as the first surface. At least one fourth surface from the multiple surfaces is between the second and third surfaces and perpendicular to the first and third surfaces. The fourth surface defines a lower half of a wall of the channel. The second part further includes a second feature at the same end of the waveguide as the first feature; the second feature defines the remaining portion of the rectangular opening not defined by the first feature.

[0021] Furthermore, this document describes an example method for fabricating a two-part folded waveguide with a horn. The method includes forming a first portion of the waveguide such that the first portion includes a first surface from a plurality of surfaces having: a sinusoidal shape folded back and forth about a longitudinal axis that travels longitudinally through a channel; and a plurality of radiating slots, each horn-shaped, the horn forming an aperture through the first surface and into the channel. Forming the first portion further includes at least one second surface from the plurality of surfaces, the second surface being perpendicular to the first surface to define an upper half of a wall of the channel perpendicular to the first surface. The first portion further includes a first feature at one end of the waveguide, the first feature defining a portion of a rectangular opening in the longitudinal direction and leading to the channel. The method further includes forming a second portion of the waveguide such that the second portion of the waveguide includes a third surface from the plurality of surfaces having the same sinusoidal shape as the first surface. Forming the second portion includes forming at least one fourth surface from the plurality of surfaces perpendicular to the third surface. The fourth surface defines a lower half of a wall of the channel. The second part further includes a second feature at the same end of the waveguide as the first feature; the second feature defines the remaining portion of the rectangular opening not defined by the first feature. The method further includes: arranging the second part of the waveguide adjacent to and parallel to the first part of the waveguide by orienting the first part and the second part of the waveguide to align the first feature of the first part of the waveguide with the second feature of the second part of the waveguide; and aligning the upper half of the wall of the channel perpendicular to the first surface of the first part of the waveguide and the lower half of the wall of the channel perpendicular to the third surface, such that the sinusoidal shapes of the first and second parts of the waveguide are aligned parallel to each other. In some examples, a gap exists between the first and second parts. In other examples, there is a zero gap (e.g., direct contact between the two parts) or a small gap filled with various types of materials. If a gap exists, it is compensated by a horn for any undesirable effects on the antenna pattern that would otherwise result.

[0022] This is just one example of the technique, system, apparatus, and method for describing a two-part folded waveguide with a horn. Other examples and implementations are described in this document.

[0023] Example device

[0024] Figure 1 An example apparatus 100 for a two-part folded waveguide 102 with a horn 124 is shown, illustrating the techniques, systems, devices, and methods according to this disclosure. The example processes described herein (including the use of...) Figure 5The process described herein forms a two-part folded waveguide 102 with a horn 124. Typically, the waveguide 102 is configured to direct energy associated with electromagnetic signals transmitted through the air to an antenna, transceiver, device, or other component that transmits or receives electromagnetic signals to perform a function, for example. For example, device 100 may be part of a sensor system (e.g., a radar system). The waveguide 102 may be integrated into the sensor system and coupled to an antenna or other component; for clarity, Figure 1 These components have been omitted.

[0025] Waveguide 102 may have multiple defined channels 104 or hollow core surfaces 110, 112, 114, and 116 for capturing the energy of electromagnetic signals transmitted through the air. Channels 104 may be filled with air or another suitable dielectric material. Channels 114 have a folded or sinusoidal shape 118 that folds back and forth about a longitudinal axis 120 that runs longitudinally along the length of waveguide 102 and the corresponding length of channel 104.

[0026] Waveguide 102 can be constructed from metal, plastic, wood, or a combination thereof. Regardless of the construction material, it may be difficult to form a waveguide with a hollow core having a sinusoidal shape 118 with channel 104.

[0027] It is desirable to form a waveguide 102 having at least two separate portions (e.g., a first portion 106 and a second portion 108). However, this may introduce gaps and other irregularities in the size or shape of the waveguide 102, which could lead to undesirable effects in the antenna pattern. As described below, even with gaps, the waveguide 102 is capable of compensating for any undesirable effects otherwise arising from forming the waveguide 102 with more than one portion. This compensation is provided at least in part by using a plurality of horn-shaped radiating slots 122. Each of the plurality of radiating slots 122 includes a longitudinal slot parallel to the longitudinal axis 120 to produce a horizontally polarized antenna pattern. The specific dimensions and locations of the radiating slots 122 can be determined using modeling and testing to achieve their positions and dimensions, thereby producing a specific desired antenna pattern.

[0028] Waveguide 102 comprises at least two portions, a first portion 106 and a second portion 108. When the first portion 106 and the second portion 108 are oriented and arranged parallel (e.g., with or without a gap between them), the first portion 106 and the second portion 108 create a channel 104. That is, the channel 104 includes an inner surface formed by surfaces 110, 112, 114, and 116 of the two portions 106 and 108. Specifically, the first portion 106 includes a first surface 110 that provides the top of the channel 104, which imparts a sinusoidal shape 118 to the channel 104 (e.g., for eliminating gradient lobes). The first surface 110 also provides a plurality of radiating slots 122, each of which is horn-shaped 124. Each of the horns 124 is configured to form an aperture through the first surface 110 and into the channel 104 to allow electromagnetic energy leakage. The horn 124 enables electromagnetic energy to escape from the channel 104, thereby filtering the electromagnetic energy retained in the channel 104 into a specific operating frequency of the channel 104 (or waveguide 102).

[0029] The first portion 106 of waveguide 102 also includes at least one second surface 112. The second surface 112 is perpendicular to the first surface 110 and is configured to define the upper half 126 of the wall of channel 104 perpendicular to the first surface 110. When aligned, the two portions 106 and 108 laterally divide waveguide 102 (e.g., in two), with the dividing direction perpendicular to the longitudinal axis 120. The first surface 110 provides: the top of channel 104 (through which the radiating slot 122 is formed), and the upper half of the walls along a sinusoidal shape 128 on both sides of channel 104.

[0030] Waveguide 102 includes an opening (e.g., a rectangular opening) in a longitudinal direction 120 at one end of channel 104, through which electromagnetic energy can enter channel 104. A first feature 128 of a first portion 106 is located at the same end of waveguide 102 as the opening. The first feature 128 defines a portion of the opening formed by a combination of a portion of a first surface 110, a portion of a second surface 112, and an upper half 126 of a wall.

[0031] A second portion 108 of waveguide 102 is arranged adjacent to and parallel to the first portion 106, thereby forming a channel 104. The second portion 108 of the waveguide includes a third surface 114 and at least one fourth surface, including a fourth surface 116. The third surface 124 may be parallel to the first surface 110 and may include the same sinusoidal shape 118 as the first surface 110. The third surface 124 can be considered as the bottom surface forming the channel 104, which is parallel to and opposite to the top surface formed by the first surface 110.

[0032] A fourth surface 116 is disposed between the second surface 114 and the third surface 116. The fourth surface 118 is perpendicular to both the first surface 110 and the third surface 116, such that the fourth surface aligns with the second surface 112. The fourth surface 116 is configured to define the remaining lower half 130 of the wall of the channel 104. In other words, the fourth surface 116 is configured to extend or lengthen the wall partially formed by the second surface 112, such that the wall is adjacent to the bottom surface of the channel 104 defined by the third surface 116. The lower half 310 of the wall meets the upper half 126 of the wall to form a consistent inner surface on either side of the channel 104, which folds back and forth in a sinusoidal shape 118.

[0033] The second portion 108 of waveguide 102 also includes a second feature 132 at the same end of the waveguide as the first feature 128. The second feature 132 defines the remaining portion of the opening of channel 104 not yet defined by the first feature 128. In other words, as... Figure 1 As shown, when the first portion 106 and the second portion 108 are arranged parallel to each other, the first feature 128 and the second feature 132 combine to form an opening in the longitudinal direction 120 through the channel 104. In other words, each of the two portions 106 and 108 may include corresponding features 128 and 132 at the same end, which together define the opening of the channel 104. The first feature 128 has a height “a” and a width “b”. The second feature 132 has the same height “a” and width “b”. The overall dimensions of the opening of the channel 104 include the total height (e.g., a+a), which is twice the width (e.g., b equals a divided by two).

[0034] Therefore, the waveguide 102 with horn 124 offers several advantages over other waveguides, including easier fabrication and a better antenna pattern free of gradient lobes or other undesirable antenna pattern characteristics that might occur when using multiple sections and forming gaps. By using a radiating slot with a specific horn shape, combined with the two-part formation of a folded or sinusoidal internal channel 104, the waveguide 102 exhibits enhanced fabrication-grade stability compared to typical waveguides.

[0035] Figure 2-1Another example of a two-part folded waveguide 102 with a horn 124 is shown, illustrating the techniques, systems, apparatus, and methods according to this disclosure. The two-part folded waveguide 102 with a horn 124 may be made from components of plastic, metal, composite materials, or wood. The waveguide 102 includes a plurality of surfaces 110, 112, 114, and 116 defining a channel 104 traveling along a longitudinal axis 120. The channel 104 has a rectangular opening 204 at one end of the waveguide 102. The rectangular opening 204 at one end of the waveguide 102 allows electromagnetic energy to enter the channel 104. Undesired wavelengths of electromagnetic energy are allowed to leak out of the waveguide 102 through a plurality of radiating slots 122 in the shape of a horn 124, thereby effectively filtering electromagnetic energy to obtain a specific operating frequency for the channel 104 (or the waveguide 102).

[0036] Multiple radiating slots 122 may be uniformly distributed along the longitudinal axis 120 and through the channel 104. The common distance 210 between each of the multiple radiating slots 122 along the longitudinal axis 120 is half (e.g., λ / 2) of the desired operating frequency or signal wavelength intended for transmission or reception using the two-part folded waveguide 102 with horn 124. This separation through the common distance 210 prevents grating lobes and ensures that undesired wavelengths of electromagnetic energy are filtered out from the specific desired operating frequency of the channel 104 (or waveguide 102). The common distance 210 is less than one wavelength of electromagnetic radiation that is not allowed to leak out of the channel 104 through the radiating slots 122.

[0037] Figure 2-2 Different lengths 212, 214, 216, 218, and 220 of a plurality of radiating slots 122 with horn 116 within a waveguide 102 according to the technology, system, apparatus, and method of this disclosure are illustrated. The different lengths 212, 214, 216, 218, and 220 allow undesired wavelengths of electromagnetic energy to leak from the waveguide 102 while ensuring that desired wavelengths of electromagnetic energy reach one end of the channel 104 opposite the rectangular opening 204. The waveguide 102 has a plurality of surfaces 110, 112, 114, and 116 that define the channel 104 traveling along a longitudinal axis 120. The dimensions and location of each of the plurality of radiating slots 122 are designed to produce a specific antenna pattern. The specific dimensions and locations of the radiating slots 122 to produce the desired specific antenna pattern can be determined by constructing and optimizing a model of the waveguide 106.

[0038] Figure 2-3A two-part folded waveguide 102 with a horn 124 is shown as another example of the technology, system, apparatus, and method according to this disclosure. A first portion 106 of the waveguide 102 is separated from a second portion 108 of the waveguide by a material layer 224, which, when measured in a direction perpendicular to the longitudinal axis 120, is less than twenty percent of the waveguide height “c” 226. The first portion 106 is measured as half the overall height “c” 226, excluding the height of the plurality of radiating slots 122 in the shape of the horn 124. The second portion 108 is measured as half the overall height “c” 226, excluding the height of the plurality of radiating slots 122 in the shape of the horn 124. The material layer 224 can be air or a dielectric material other than air. The material layer 224 is introduced because the waveguide 102 with the horn 124 is formed from the two portions.

[0039] The figure shows an individual horn 228 on waveguide 102 from a horn-shaped radiating slot 122. The horn-shaped radiating slot 122 allows the first portion 106 of waveguide 102 to be constructed with additional structural stability resulting from the enhanced thickness 230 of waveguide 102. Structural stability ensures the quality of manufacturing millimeter-sized waveguide 102, which would otherwise suffer from gradient lobes due to manufacturing defects. The enhanced structural stability addresses the problem of supporting the formation of small waveguides 102 at the scale required by industries that require improved antenna characteristics (e.g., millions of elements), and this enhanced structural stability is compensated for by providing an affordable waveguide solution using the horn 124.

[0040] Figure 3 An example 300 of a two-part folded waveguide 102 with a horn 124 is shown. An example technique for securing the two-part folded waveguide 102 with the horn 124 according to the technology, system, apparatus, and method of this disclosure utilizes a double-sided adhesive 302. In another example, the first portion 106 of the waveguide can be secured to the second portion 108 of the waveguide by an external fastener 304. The external fastener 304 may include a plastic fastener or a metal fastener. In yet another example, the first portion 106 of the waveguide can be secured to the second portion 108 of the waveguide by an internal fastener 306. The internal fastener 306 may include a plastic fastener or a metal fastener.

[0041] Waveguide 102 can be formed using one or more of the above-described techniques combined with other techniques to maintain alignment and separation between the two portions 106 and 108. The addition of a plurality of radiating slots 122 in the shape of a horn 124 results in an increased thickness 230 of waveguide 102, providing enhanced structural stability to waveguide 102 and enhancing the effectiveness of external fasteners 304 and internal fasteners 306 in securing the first portion 106 to the second portion 108 of waveguide 102.

[0042] Figure 4 Different shapes of horn 400 are shown according to the technology, system, apparatus, and method according to this disclosure. Individual radiating slots 122 may include different horn shapes. For example, Figure 4 Examples include a radiating slot 122-1 shaped like a horn 124-1, where the horn 124-1 is a triangular pyramidal horn 402. Another example of a radiating slot 122-2 is shaped like a horn 124-2, where the horn 124-2 is a square pyramidal horn 404. A radiating slot 122-3 is shaped like a horn 124-3, where the horn 124-3 is a pentagonal pyramidal horn 406. A radiating slot 122-4 is shaped like a horn 124-4, where the horn 124-4 is a hexagonal pyramidal horn 408. A radiating slot 122-5 is shaped like a horn 124-5, where the horn 124-5 is a circular pyramidal horn 410. Finally, a radiating slot 122-6 is shown that is shaped like a horn 124-6, where the horn 124-6 is a rectangular pyramidal horn 412. Waveguide 102 can utilize the same horn structure for each radiating slot (e.g., each radiating slot is a pentagonal pyramidal horn). Alternatively, waveguide 102 can utilize a variety of horn structures for each radiating slot (e.g., some horn structures are in the shape of a triangular pyramidal horn 402, while others are in a different shape). In any case, the size and shape of horn 124 can be selected, including any of the horn shapes (402, 404, 406, 408, 410, and 412), making it easy to manufacture in millimeter dimensions or smaller while still achieving the desired antenna effect.

[0043] Example Method

[0044] Figure 5 An example method for manufacturing a two-part folded waveguide 102 with a horn 124, based on the techniques, systems, apparatus, and methods described herein, is depicted. Process 500 is shown as a set of operations 502 to 506 performed in a sequence or combination of operations shown or described. Furthermore, any of operations 502 to 506 may be repeated, combined, or rearranged to provide other methods. In the various sections of the following discussion, reference may be made to environment 100 and the entities detailed above, which are referred to by way of example only. The technique is not limited to being performed by one or more entities.

[0045] At 502, each portion of the two-part folded waveguide with horn is formed. For example, the two portions of the two-part folded waveguide 102 with horn 124 can be formed by stamping, etching, cutting, machining, casting, molding, or some other method resulting in enhanced stability provided by horn 124. At 504, each portion of the two portions of the waveguide 102 with horn 124 is aligned. Optimal alignment ensures that the waveguide 102 operates without being affected by gradient lobes caused by manufacturing defects. At 506, each portion of the two portions of the waveguide with horn is secured. The two portions of the two-part folded waveguide 102 with horn 124 can be secured by external fasteners 304 or internal fasteners 306 (including plastic fasteners, metal fasteners, or double-sided adhesive).

[0046] In various aspects, the method may include manufacturing two portions of a two-part folded waveguide 102 with a horn 124 having multiple surfaces 110, 112, 114, and 116, which define a channel 104 at least by forming a first portion 106 of the waveguide 102. The first portion 106 of the waveguide 102 includes a first surface 110 from one of the multiple surfaces 110, 112, 114, and 116. The first surface 110 is shown having a folded or sinusoidal shape 118 that folds back and forth about a longitudinal axis 120, which travels along the longitudinal axis 120 of the first portion 106. The waveguide 102 also has multiple radiating slots 122, each radiating slot 122 being horn-shaped. The horn 124 is configured to form an aperture through the first surface 110 and into the channel 104. When waveguide 102 filters electromagnetic energy into a specific frequency range of channel 104, horn 124 enables electromagnetic energy to escape from channel 104.

[0047] The first portion 106 of waveguide 102 has at least one second surface 128 from a plurality of surfaces 110, 112, 114, and 116. The second surface 128 is perpendicular to the first surface 110 and is configured to define an upper half 126 of a wall of channel 104 perpendicular to the first surface 110. The first portion 106 also includes a first feature 128 at one end of waveguide 102, the first feature 128 defining a portion of a rectangular opening in the longitudinal direction leading to channel 104.

[0048] A second portion 108 of waveguide 102 may be arranged adjacent to and parallel to the first portion 106. The second portion 108 of the waveguide includes a third surface 124 from a plurality of surfaces 110, 112, 114, and 116. The third surface 124 may be parallel to the first surface 110 and may include the same sinusoidal shape 118 as the first surface 110. The second portion 108 of waveguide 102 includes at least a fourth surface 132 from the plurality of surfaces 110, 112, 114, and 116, the fourth surface 132 being between the second surface 128 and the third surface 124. The fourth surface 132 is perpendicular to the first surface 110 and the third surface 124, and defines the lower half 130 of the wall of channel 104. The second portion 108 of waveguide 102 includes a second feature 132 at the same end of the waveguide as the first feature 128, the second feature defining the remaining portion of the rectangular opening not defined by the first feature 128.

[0049] In another aspect, the method may include arranging a second portion 108 of waveguide 102 adjacent to and parallel to a first portion 106 of waveguide 102. The first portion 106 and the second portion 108 of waveguide 102 are oriented to align a first feature 128 of the first portion of waveguide 108 with a second feature 132 of the second portion of waveguide 102. An upper half 126 of the channel 104 wall perpendicular to a first surface 110 of the first portion 106 and a lower half 130 of the channel 104 wall perpendicular to a third surface 124 are aligned such that the sinusoidal shapes 118 of the first and second portions of the waveguide are aligned in parallel. Arranging the second portion 108 of waveguide 102 adjacent to and parallel to the first portion 106 of waveguide may include uniformly separating the first portion 106 of waveguide from the second portion 108 of waveguide 102 by a material layer 224, the material layer 224 having a measured size less than 20 percent of the total size of the channel 104 defined by the lower and upper halves of the wall.

[0050] A first portion 106 of waveguide 102 is secured to a second portion 108 of waveguide 102 using fasteners, which maintain the first portion 106 and the second portion 108 of waveguide 102 in a parallel arrangement. The fasteners can be external fasteners 304 or internal fasteners 306. The fasteners can be plastic or metal fasteners. The first portion 106 of the waveguide can be secured to the second portion 108 of waveguide 102 using an adhesive bond between the second and fourth surfaces. The first portion 106 and the second portion 108 of waveguide 102 can also be secured using an adhesive bond between the second surface 128 and the fourth surface 132. The adhesive bond can be a dielectric, epoxy resin, glue, or double-sided tape 302.

[0051] Example image

[0052] Figure 6 Figure 600 illustrates the antenna characteristics according to the techniques, systems, apparatus, and methods of this disclosure. For example, Figure 600 includes a reflection coefficient (dB(S(1,1)) 602 on the y-axis and a frequency (GHz) 604 on the x-axis. A small reflection coefficient 602 indicates a low total reflectivity. In all aspects, the effective waveguide exhibits a reflection coefficient below -10 dB. In Figure 600, the two-part folded waveguide 102 with horn 124 exhibits a reflection coefficient below -10 dB between 75.5 GHz and 77.50 GHz 606.

[0053] Figure 7 Another figure 700 illustrates the antenna characteristics according to the techniques, systems, apparatus, and methods of this disclosure. For example, Figure 700 includes a normalized decibel level (dB 10 normalized (total gain)) indicating the antenna gain on the y-axis and θ (Theta) (deg) 704 of the line of sight on the x-axis. Figure 700 includes a wide beam pattern 706 and a narrow beam pattern 708. In various aspects, the effective waveguide exhibits low sidelobes (e.g., less than -20 dB). In Figure 700, the two-part folded waveguide 102 with horn 124 exhibits low sidelobes less than -20 dB for a 0-degree line of sight.

[0054] Additional examples

[0055] Additional examples of folded waveguides for antennas are provided in the following sections.

[0056] Example 1. An apparatus comprising a two-part folded waveguide having a plurality of surfaces defining a channel, the two-part folded waveguide comprising: a first portion of the waveguide including: a first surface from the plurality of surfaces having: a sinusoidal shape folded back and forth about a longitudinal axis that travels through the channel in a longitudinal direction; and a plurality of radiating slots, each radiating slot being horn-shaped, the horn forming an aperture through the first surface and into the channel; at least one second surface from the plurality of surfaces, the second surface being perpendicular to the first surface to define an upper half of a wall of the channel perpendicular to the first surface; and a first feature at one end of the waveguide, the second surface being... A feature defines a portion of a rectangular opening in the longitudinal direction leading to a channel; a second portion of the waveguide, arranged adjacent to and parallel to the first portion, the second portion of the waveguide comprising: a third surface from a plurality of surfaces, the third surface being parallel to the first surface and having the same sinusoidal shape as the first surface; at least one fourth surface from a plurality of surfaces, the fourth surface being between the second and third surfaces, the fourth surface being perpendicular to the first and third surfaces, the fourth surface defining a lower half of a wall of the channel; and a second feature at the same end of the waveguide as the first feature, the second feature defining the remaining portion of the rectangular opening not defined by the first feature.

[0057] Example 2. Any of the aforementioned examples, wherein a first portion of the waveguide is uniformly separated from a second portion of the waveguide by a layer of material.

[0058] Example 3. Any of the preceding examples, wherein a first portion of the waveguide is uniformly separated from a second portion of the waveguide by a material layer, the material layer having a measured dimension less than twenty percent of the total dimension of the channel defined by the lower and upper halves of the wall.

[0059] Example 4. Any of the aforementioned examples of the apparatus, wherein the material layer separating the first portion of the waveguide from the second portion of the waveguide comprises air.

[0060] Example 5. Any of the foregoing examples, wherein the material layer separating the first portion of the waveguide from the second portion of the waveguide comprises a dielectric material other than air, the dielectric material being configured to: hold the first portion of the waveguide in a fixed position relative to the second portion of the waveguide.

[0061] Example 6. Any of the preceding examples, wherein a first portion of the waveguide is secured to a second portion of the waveguide by a metal fastener configured to hold the first portion of the waveguide in a fixed position relative to the second portion of the waveguide.

[0062] Example 7. Any of the foregoing examples, wherein a first portion of the waveguide is secured to a second portion of the waveguide by plastic fasteners configured to: hold the first portion of the waveguide in a fixed position relative to the second portion of the waveguide.

[0063] Example 8. Any of the foregoing examples, wherein a first portion of the waveguide is fixed to a second portion of the waveguide by a double-sided adhesive configured to hold the first portion of the waveguide in a fixed position relative to the second portion of the waveguide.

[0064] Example 9. Any of the foregoing examples of the device in which the two-part folded waveguide comprises one or more materials, including plastic, metal, composite material or wood.

[0065] Example 10. Any of the foregoing examples of a device in which the plurality of radiating slots include different horn shapes, including: a triangular pyramidal horn; a square pyramidal horn; a pentagonal pyramidal horn; a hexagonal pyramidal horn; a circular pyramidal horn; or a rectangular pyramidal horn.

[0066] Example 11. Any of the preceding examples, wherein a plurality of radiating slots are uniformly distributed between a rectangular opening and one end of a waveguide, the one end of which is arranged to be opposite the rectangular opening along a longitudinal axis that travels through the channel in the longitudinal direction.

[0067] Example 12. Any of the aforementioned examples, wherein the common distance between each horn along the longitudinal axis is λ / 2.

[0068] Example 13. A method comprising: manufacturing two portions of a two-part folded waveguide having a plurality of surfaces defining a channel and having a horn, at least by: forming a first portion of the waveguide such that the first portion includes: a first surface from the plurality of surfaces having: a sinusoidal shape folded back and forth about a longitudinal axis that travels through the channel in a longitudinal direction; and a plurality of radiating slots, each radiating slot being horn-shaped, the horn forming an aperture through the first surface and into the channel; at least one second surface from the plurality of surfaces, the second surface being perpendicular to the first surface to define an upper half of a wall of the channel perpendicular to the first surface; and a first feature at one end of the waveguide defining a portion of a rectangular opening in the longitudinal direction leading to the channel; forming a second portion of the waveguide such that the second portion of the waveguide includes A third surface from a plurality of surfaces, the third surface having the same sinusoidal shape as the first surface; at least one fourth surface from a plurality of surfaces, the fourth surface being perpendicular to the third surface and defining the lower half of the wall of the channel; and a second feature at the same end of the waveguide as the first feature, the second feature defining the remaining portion of the rectangular opening not defined by the first feature; and arranging the second portion of the waveguide adjacent to and parallel to the first portion of the waveguide by: orienting the first portion of the waveguide and the second portion of the waveguide to align the first feature of the first portion of the waveguide with the second feature of the second portion of the waveguide; and aligning the upper half of the wall of the channel perpendicular to the first surface of the first portion of the waveguide and the lower half of the wall of the channel perpendicular to the third surface, such that the sinusoidal shapes of the first and second portions of the waveguide are aligned parallel to each other.

[0069] Example 14. Any of the methods in the preceding examples, wherein arranging the second portion of the waveguide adjacent to and parallel to the first portion of the waveguide comprises: uniformly separating the first portion of the waveguide from the second portion of the waveguide by a material layer, the material layer having a measured size less than twenty percent of the total size of the channel defined by the lower and upper halves of the wall.

[0070] Example 15. Any of the methods in the preceding examples, wherein forming each of the first and second portions of the waveguide includes using injection molding.

[0071] Example 16. Any of the methods in the foregoing examples further includes: in response to arrangement, fixing a first portion of the waveguide to a second portion of the waveguide.

[0072] Example 17. Any of the methods in the preceding examples, wherein securing the first portion of the waveguide to the second portion of the waveguide includes securing it with fasteners that hold the first and second portions of the waveguide in a parallel arrangement.

[0073] Example 18. Any of the methods in the preceding examples, wherein the fastener includes at least one of a plastic fastener or a metal fastener.

[0074] Example 19. Any of the methods in the preceding examples, wherein fixing the first portion and the second portion of the waveguide comprises: fixing by means of generating an adhesive joint between the second surface and the fourth surface.

[0075] Example 20. Any of the methods in the preceding examples, wherein producing an adhesive joint includes using a dielectric, epoxy resin, glue, or double-sided tape.

[0076] Conclusion

[0077] 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 spirit and scope of the present disclosure as defined by the following claims.

[0078] Unless the context clearly specifies otherwise, the use of "or" and grammatically related terms indicates an unrestricted, non-exclusive alternative. As used herein, the phrase referring to "at least one" of a list of items means any combination of those items, including a single member. For example, "at least one of a, b, or c" is intended to cover: a, b, c, ab, ac, bc, and abc, as well as any combination with multiple identical elements (e.g., aa, aaa, aab, aac, abb, acc, bb, bbb, bbc, cc, and ccc, or any other ordering of a, b, and c).

Claims

1. An apparatus comprising a two-part folded waveguide with a horn and a plurality of surfaces defining a channel, the two-part folded waveguide comprising: A first metal injection molding portion, the first metal injection molding portion comprising: A first surface derived from the plurality of surfaces, the first surface having: A sinusoidal shape, the sinusoidal shape folding back and forth around a longitudinal axis, the longitudinal axis traveling the channel in the longitudinal direction; and Multiple radiating slots, each of which is horn-shaped, the horn forming an opening that passes through the first surface and enters the channel; At least one second surface from the plurality of surfaces, the second surface being perpendicular to the first surface to define the upper half of the wall of the channel perpendicular to the first surface; and A first feature at one end of the waveguide, the first feature defining a portion of a rectangular opening in the longitudinal direction and leading to the channel; A second metal injection molding portion, arranged adjacent to and parallel to the first metal injection molding portion, the second metal injection molding portion comprising: A third surface derived from the plurality of surfaces, the third surface being parallel to the first surface and having the same sinusoidal shape as the first surface; At least one fourth surface from the plurality of surfaces, the fourth surface being between the second surface and the third surface, the fourth surface being perpendicular to the first surface and the third surface, the fourth surface defining the lower half of the wall of the channel; and A second feature at the same end of the waveguide as the first feature, the second feature defining the remaining portion of the rectangular opening not defined by the first feature.

2. The apparatus as claimed in claim 1, characterized in that, The first metal injection-molded portion of the waveguide is uniformly separated from the second metal injection-molded portion of the waveguide through a material layer.

3. The apparatus as described in claim 2, characterized in that, The material layer separating the first metal injection-molded portion of the waveguide from the second metal injection-molded portion of the waveguide includes air.

4. The apparatus as claimed in claim 2, characterized in that, The material layer separating the first metal injection-molded portion of the waveguide from the second metal injection-molded portion of the waveguide comprises a dielectric material other than air, to hold the first metal injection-molded portion of the waveguide in a fixed position relative to the second metal injection-molded portion of the waveguide.

5. The apparatus as described in claim 2, characterized in that, The first metal injection-molded portion of the waveguide is fixed to the second metal injection-molded portion of the waveguide by metal fasteners, the metal fasteners being configured to: hold the first metal injection-molded portion of the waveguide in a fixed position relative to the second metal injection-molded portion of the waveguide.

6. The apparatus as claimed in claim 2, characterized in that, The first metal injection-molded portion of the waveguide is secured to the second metal injection-molded portion of the waveguide by plastic fasteners, the plastic fasteners being configured to: hold the first metal injection-molded portion of the waveguide in a fixed position relative to the second metal injection-molded portion of the waveguide.

7. The apparatus as claimed in claim 2, characterized in that, The first metal injection-molded portion of the waveguide is fixed to the second metal injection-molded portion of the waveguide by a double-sided adhesive, the double-sided adhesive being configured to: hold the first metal injection-molded portion of the waveguide in a fixed position relative to the second metal injection-molded portion of the waveguide.

8. The apparatus as claimed in claim 1, characterized in that, The first metal injection-molded portion of the waveguide is uniformly separated from the second metal injection-molded portion of the waveguide by a material layer, wherein the measured size of the material layer is less than 20 percent of the total size of the channel defined by the lower and upper halves of the wall.

9. The apparatus as claimed in claim 1, characterized in that, The two folded waveguides are made of metallic materials.

10. The apparatus as claimed in claim 1, characterized in that, The plurality of radiating slots include different horn shapes, including: A triangular pyramidal trumpet; A square-shaped pyramidal trumpet; A pentagonal pyramidal trumpet shape; A hexagonal pyramidal trumpet; A round, pyramidal trumpet shape; or A rectangular pyramidal trumpet.

11. The apparatus as claimed in claim 1, characterized in that, The plurality of radiation slots are evenly distributed between the rectangular opening and one end of the waveguide, and one end of the waveguide is arranged to be opposite the rectangular opening along the longitudinal axis, which travels through the channel in the longitudinal direction.

12. The apparatus as claimed in claim 1, characterized in that, The common distance between each horn along the longitudinal axis is λ / 2.

13. A method for a waveguide, the method comprising: A two-part device is manufactured from two metal sections. The two-part device includes a folded waveguide with multiple radiating slots in a horn shape. The horn provides an aperture into a sinusoidal channel to guide electromagnetic energy between the metal sections. The channel includes multiple folds for guiding the electromagnetic energy back and forth about a longitudinal axis traveling in the longitudinal direction to leak unwanted energy along the length of the channel. Manufacturing the two-part device includes: A first metallic portion is formed as the upper half of the waveguide, such that the first metallic portion includes: A first surface, the first surface having a sinusoidal top, to support the aperture provided by the horn of the radiating groove; At least one second surface, perpendicular to the first surface, to form the upper half of the opposing wall of the channel; and A first feature at one end of the channel defines a portion of a rectangular opening through the channel in the longitudinal direction; A second metallic portion of the waveguide is formed as the lower half of the waveguide, such that the second metallic portion includes: A third surface having the same sinusoidal shape as the top surface; At least one fourth surface, said fourth surface being perpendicular to said third surface, to form the lower half of said opposing wall; and A second feature at the same end of the channel as the first feature defines the remaining portion of the rectangular opening not defined by the first feature; The second metal portion is arranged to be adjacent to and parallel to the first metal portion by the following operations: Orient the first metal portion and the second metal portion to align the first feature with the second feature; and The upper half of the opposing wall is positioned adjacent to the lower half of the opposing wall such that the surfaces of each sinusoidal shape of the first metal portion and the second metal portion are aligned parallel to each other.

14. The method as described in claim 13, characterized in that, Arranging the second metal portion adjacent to and parallel to the first metal portion includes: uniformly separating the first metal portion and the second metal portion by a material layer, the material layer having a measured dimension less than 20 percent of the total dimension of the channel defined by the lower and upper halves of the wall.

15. The method of claim 13, further comprising: In response to the arrangement, the first part of the waveguide is fixed to the second part of the waveguide.

16. The method as described in claim 15, characterized in that, Securing the first portion of the waveguide to the second portion of the waveguide includes securing it with fasteners that keep the first and second portions of the waveguide arranged in parallel.

17. The method as described in claim 16, characterized in that, Fasteners include at least one of plastic fasteners or metal fasteners.

18. The method as described in claim 15, characterized in that, Fixing the first portion and the second portion of the waveguide includes fixing them by creating an adhesive joint between the second surface and the fourth surface.

19. The method as described in claim 18, characterized in that, The adhesive bonding process includes using dielectrics, epoxy resins, adhesives, or double-sided tapes.

20. A system for a waveguide, the system comprising means for performing the method as described in any one of claims 13 to 19.

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