Waveguide antenna for waveguiding and method for producing a waveguide antenna

Abstract

The present invention provides a waveguide antenna (10) for waveguiding, comprising a plurality of sheets (B1; ...; Bn), wherein at least some of the sheets (B1; ...; Bn) each have predetermined punching structures (SK), and wherein the sheets (B1; ...; Bn) are arranged on top of one another to form a stack (ST) in a direction (x) perpendicular to a sheet surface, wherein at least one antenna channel (AK) is formed by the stacked sheets (B1; ...; Bn) by means of the punched structures (SK).

Description

[0001] The present invention relates to a waveguide antenna for waveguiding and a method for manufacturing a waveguide antenna. State of the art

[0002] Conventional waveguide antennas for radar antenna systems can be modular in design. Waveguides for radar signals are also arranged within the modules.

[0003] Waveguides can be used to transmit high-frequency signals and are becoming increasingly important for applications in the automotive sector, where the requirements for detecting and distinguishing different objects are constantly increasing.

[0004] A planar two-dimensional waveguide antenna is known for this purpose. In conventional methods, such an antenna can be implemented, for example, in a three-plate design.

[0005] By joining the two-dimensional plates, an internal structure consisting of waveguides and radiating openings or apertures is created. The radar signals can be transmitted within the waveguide and coupled in and / or out via openings on a side or top surface of the antenna.

[0006] For various reasons, such as performance, size and cost, the above-mentioned design may be difficult to meet the increasing requirements.

[0007] Today's waveguide antennas use two-dimensionally coated plastic parts that are bonded or soldered together to transmit radar waves. Two coated plastic parts may be used, with the channels sealed by joining the two halves. Common designs have their manufacturing process as a constraint on the radar geometry.

[0008] DE 10 2012 215 083 A1 describes an antenna comprising a plurality of plate elements and a corresponding method for manufacturing such an antenna. To construct such an antenna, the metallized plate elements are arranged one behind the other in one direction, with the aperture area of ​​the antenna being formed by the plate elements arranged one behind the other.

[0009] All of these designs have constraints during the manufacturing process that limit the radar geometry. Some processes are redundant. Disclosure of the invention

[0010] The present invention provides a waveguide antenna for waveguiding according to claim 1 and a method for manufacturing a waveguide antenna according to claim 10.

[0011] Preferred further training is the subject of the subclaims. Advantages of the invention

[0012] The idea underlying the present invention is that a multi-layer construction for waveguide antennas can be realized by stacking sheet metal parts to form laminated cores.

[0013] This advantageously allows radar channels of a waveguide antenna to be freely designed and completed in compact steps, eliminating the need for subsequent assembly of the sheets. Additional subsequent process steps, such as gluing, screwing, etc., can also be eliminated.

[0014] The punched structures can extend through the respective sheet and form one or more antenna channels inside an antenna block after the sheets have been stacked.

[0015] Last but not least, the invention offers a compact installation space with increased design freedom for the antenna and also increases the antenna performance with a reduction in costs for future waveguide antennas.

[0016] Performance can be increased, with ranges being increased and radiation and reception angles being increased.

[0017] Through a simplified manufacturing process, costs can be reduced, the installation space can be reduced while simultaneously increasing performance and the design freedom can be increased.

[0018] According to the invention, the waveguide antenna for waveguiding comprises a plurality of sheets, wherein at least some of the sheets each have predetermined punched structures, and wherein the sheets are arranged on top of one another to form a stack in a direction perpendicular to a sheet surface, wherein at least one antenna channel is formed by the stacked sheets by means of the punched structures.

[0019] The waveguide antenna can thus be constructed from multiple sheets perpendicular to one direction, each with a different stamped structure. Shapes such as "ridge elements" for ridged waveguides can be created using the manufacturing technology—undercuts and cavities—that are not possible with plastic injection molding. Thus, at least one antenna channel can be designed with a free design.

[0020] According to a preferred embodiment of the waveguide antenna, the stacked sheets comprise at least an upper cover plate and a lower cover plate. The upper and / or lower cover plate can also represent a printed circuit board (PCB).

[0021] The upper and lower cover plates can serve as closures to close the internal waveguiding structure in the waveguide antenna.

[0022] According to a preferred embodiment of the waveguide antenna, a channel height of the at least one antenna channel is defined by a predetermined sheet thickness of the sheets and number of sheets.

[0023] In this way, a precisely defined distance can be set.

[0024] According to a preferred embodiment of the waveguide antenna, the at least one antenna channel is designed as a rectangular waveguide or a ridge waveguide.

[0025] Compared to a rectangular waveguide with the same external dimensions, a ridge waveguide can have a much lower cutoff frequency of its fundamental mode. With the same cutoff frequency of the fundamental mode, the cross-section of a ridge waveguide can be much smaller than that of a rectangular waveguide. This enables compact designs for the waveguide antenna.

[0026] According to a preferred embodiment of the waveguide antenna, a cross-sectional shape and / or cross-sectional size of the at least one antenna channel varies over its course.

[0027] The cross-sectional shape of an antenna channel doesn't have to be limited to a rectangle. Circular, elliptical, or even irregular cross-sections are possible. By using different geometries along the antenna channel, the resulting degrees of freedom can be used to precisely control the waves and increase performance.

[0028] According to a preferred embodiment of the waveguide antenna, the sheets comprise aluminum and / or copper materials and / or an alloy thereof and / or stainless steel and / or steel.

[0029] Suitable materials include all aluminum and / or copper materials and / or an alloy thereof and / or stainless steel and / or steel that are suitable for punching.

[0030] According to a preferred embodiment of the waveguide antenna, all sheets have the same height.

[0031] According to a preferred embodiment of the waveguide antenna, the at least one antenna channel extends at least partially along at least one of three orthogonal spatial directions.

[0032] According to a preferred embodiment, the waveguide antenna is designed to guide radar waves.

[0033] Advantageously, the radar waves can be forwarded into the freely formed antenna channels and coupled in and / or out via the aperture openings.

[0034] According to the invention, the method for producing a waveguide antenna comprises providing a plurality of sheets, at least some of the sheets each having predetermined punched structures; stacking the sheets on top of one another in a direction perpendicular to a sheet surface to form a stack, wherein at least one antenna channel is formed by the stacked sheets by means of the punched structures.

[0035] Several sheets with a punched structure are produced and stacked using a conventional punching process, or in the same step from sheet metal parts to sheet metal packages.

[0036] This process allows for a wide range of radar channel design options. Compared to plastic injection molding, the channel height spacing can be optimized, and the manufacturing technology used also allows for the creation of undercuts and caverns, such as "ridge elements" for ridged waveguides.

[0037] To increase performance (including cost reduction), the waveguides can be designed with different paths in a flexible manner.

[0038] According to a preferred embodiment of the method, the sheets with the punched structures are produced by a punching process and the sheets are stacked into a stack by a packaging process.

[0039] The waveguide antenna can be advantageously manufactured using the stacking process in sheet metal processing. This eliminates the need for subsequent assembly of the sheets, which is necessary in other antenna manufacturing processes.

[0040] According to a preferred embodiment of the method, at least two sheets are soldered together.

[0041] To further optimize the reflection of radar waves at the punching indentations of the stacked sheets, the sheets can be soldered together using a suitable solder surface. This eliminates an air gap between the sheets and further reduces power losses. In the case of steel sheets, for example, a nickel strike layer can be applied as an adhesion promoter, followed by a tin layer to achieve the required skin depth.

[0042] The method can also be advantageously characterized by the features of the waveguide antenna already mentioned and vice versa.

[0043] Further features and advantages of embodiments of the invention will become apparent from the following description with reference to the accompanying drawings. Short description of the drawings

[0044] The present invention is explained in more detail below with reference to the exemplary embodiments shown in the schematic figures of the drawing.

[0045] They show: Fig. 1 is a schematic exploded view of a plurality of sheets for constructing a waveguide antenna according to an embodiment of the present invention; and Fig. 2 is a schematic representation of stacked intermediate sheets and internal antenna channels in a cross-section according to an embodiment of the present invention; Fig. 3 is a block diagram of method steps of a method for manufacturing a waveguide antenna according to an embodiment of the present invention.

[0046] In the figures, the same reference symbols denote the same or functionally identical elements.

[0047] Fig. Figure 1 shows a schematic exploded view of a stack according to the present invention.

[0048] The stack comprises a plurality of sheets B1, ... Bn, which are arranged one above the other to construct a waveguide antenna 10, as shown in Fig. 1. Some or all of the sheets B1, ... Bn may have a stamped structure SK.

[0049] All punchable metals and their alloys can be used to produce sheets B1, ... Bn.

[0050] The sheets B1, ... Bn can be further divided into three groups, specifically as upper cover plates AP-O, as intermediate plates, and as lower cover plates AP-U. The stack comprises at least one upper cover plate AP-O and one lower cover plate AP-U. Alternatively, the upper and / or lower cover plates can also be represented by a printed circuit board (PCB).

[0051] The sheets B1, ..., Bn with the stamped structures SK can be manufactured using a conventional stamping process. The structures of the waveguide antenna 10, for example, waveguides and apertures, are formed by stacking the sheets B1, ..., Bn or the stamped structures SK formed thereon, wherein the sheets B1, ..., Bn are arranged one on top of the other in a predetermined direction, preferably in a direction x perpendicular to a sheet surface.

[0052] Aperture openings A may be present in the upper and / or lower cover plates AP-O / AP-U through which the waves can escape.

[0053] Antenna channels AK can be formed by stacking the punched structures SK in the intermediate plates. The antenna channels AK are defined by the punched structures SK punched on the sheets B1, ..., Bn. These punched structures SK can be different on the sheets B1, ..., Bn. The stacked cover plates AP-O and AP-U, or alternatively, printed circuit boards, can each serve as covers for the antenna channels AK.

[0054] By using the stacking process in sheet metal processing, antenna ducts can be freely designed and completed in a single step. Subsequent assembly of the sheets is therefore unnecessary. Subsequent process steps such as gluing, screwing, and welding can be eliminated.

[0055] By using thin sheet metal, approximately 0.25 mm thick, the spacing of the channel heights can be optimally designed. This manufacturing technology also allows for the creation of undercuts and cavities, which are not possible with plastic injection molding.

[0056] All punchable aluminum and copper materials, as well as their alloys, are particularly suitable for sheet metal. However, stainless steel and / or steel can also be used, provided the surface is suitable (resistivity less than or equal to 0.1 µ Ω *m).

[0057] To further optimize the reflection of radar waves at the punching indentations of the stacked sheets, the sheets can be soldered together using a suitable solder surface. To prevent an air gap between the sheets, all individual sheets can be soldered together using a suitable solder surface. In the case of steel sheets, for example, a nickel strike layer can be applied as an adhesion promoter, followed by a tin layer. It is important to ensure that the required skin depth can be represented.

[0058] Fig. 2 shows the cut-out intermediate plates with punched structures SK for constructing the antenna channels AK in a waveguide antenna 10. The internal structure of the waveguide antenna 10 is shown in two parts on the two sides of a cross-section Q.

[0059] The cross-section Q illustrates the construction of the stack ST. The waveguide antenna 10 consists of several sheets B1, ..., Bn arranged one above the other in the direction x perpendicular to the sheet surface. The antenna channels AK in the waveguide antenna 10 can be formed as waveguides. The shapes of the antenna channels AK can be rectangular, elliptical, even irregular, etc. In the area of ​​the aperture openings A on the top / bottom side, openings to the antenna channels AK are provided. There, the path of an antenna channel AK connects to the aperture openings A. The radar signals can be coupled in and / or out via these.

[0060] Fig. 3 shows a block diagram of method steps of a method for manufacturing a waveguide antenna according to an embodiment of the present invention.

[0061] In the method for producing a waveguide antenna, a plurality of sheets is provided S1, wherein at least some of the sheets each have predetermined punched structures; a stacking S2 of the sheets on top of one another in a direction x perpendicular to a sheet surface to form a stack, wherein at least one antenna channel is formed by the stacked sheets by means of the punched structures.

[0062] After the sheet metal parts have been processed into sheet metal packages, material-to-material joining can be used to prevent air gaps from forming between the sheets.

[0063] Although the present invention has been fully described above using the preferred embodiment, it is not limited thereto but can be modified in many ways. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2012 215 083 A1

[0008]

Claims

[1] Waveguide antenna (10) for waveguiding, comprising, a plurality of sheets (B1; ...; Bn), wherein at least some of the sheets (B1; ...; Bn) each have predetermined punching structures (SK), and wherein the sheets (B1; ...; Bn) are arranged on top of one another to form a stack (ST) in a direction (x) perpendicular to a sheet surface, wherein at least one antenna channel (AK) is formed by the stacked sheets (B1; ...; Bn) by means of the punched structures (SK). [2] Waveguide antenna (10) according to claim 1, wherein the stacked sheets (B1; ...; Bn) comprise at least one upper cover plate (AP-O) and one lower cover plate (AP-U). [3] Waveguide antenna (10) according to one of claims 1 to 2, wherein a channel height of the at least one antenna channel (AK) is defined by a predetermined sheet thickness and number of sheets (B1; ...; Bn). [4] Waveguide antenna (10) according to one of claims 1 to 3, wherein the at least one antenna channel (AK) is designed as a rectangular waveguide or a ridge waveguide. [5] Waveguide antenna (10) according to one of claims 1 to 4, wherein a cross-sectional shape and / or cross-sectional size of the at least one antenna channel (AK) varies in its course. [6] Waveguide antenna (10) according to one of claims 1 to 5, wherein the sheets (B1; ...; Bn) comprise an aluminum and / or copper material and / or an alloy thereof and / or stainless steel and / or steel. [7] Waveguide antenna (10) according to one of claims 1 to 6, wherein all sheets (B1; ...; Bn) have the same height. [8] Waveguide antenna (10) according to one of claims 1 to 7, wherein the at least one antenna channel (AK) extends at least partially along at least one of three orthogonal spatial directions. [9] Waveguide antenna (10) according to one of claims 1 to 7, which is designed to guide radar waves. [10] A method for manufacturing a waveguide antenna (10), comprising the steps of: - Providing (S1) a plurality of sheets (B1; ...; Bn), wherein at least some of the sheets (B1; ...; Bn) each have predetermined punching structures (SK); - stacking (S2) the sheets (B1; ...; Bn) in a direction (x) perpendicular to a sheet surface on top of each other to form a stack (ST), wherein the stacked sheets (B1; ...; Bn) at least one antenna channel (AK) is formed by means of the punched structures (SK). [11] Method according to claim 10, wherein the sheets (B1; ...; Bn) with the punched structures (SK) are produced by a punching process and the sheets (B1; ...; Bn) are stacked into a stack (ST) by a packaging process. [12] Method according to one of claims 10 and 11, in which at least two sheets (B1; B1) are soldered together.

Images