Additively fabricated electrical transmission line, and manufacturing method

Abstract

An additively fabricated electrical transmission line is formed as a single, unified, continuous, monolithic additively fabricated material part and includes an outer housing defining a cavity inside, a conductive stripline passing through this cavity, and a stub in the cavity electrically coupling the outer housing to the stripline. The stripline may be a flat stripline. The stub may be angled with respect to the stripline, which facilitates surface treatment within the housing (e.g., polishing to reduce surface roughness), which may be part of the manufacturing method of the electrical transmission line. The electrical transmission line may be part of an electrical installation comprising a plurality of such electrical transmission lines, which may have various shapes, including curved shapes, to establish desired electrical connections between components.

Description

Technical Field

[0001] (Reference to Related Applications) This patent application claims the benefit of U.S. Patent Application No. 18 / 640,815, filed Apr. 19, 2024, and U.S. Provisional Patent Application No. 63 / 502,734, filed May 17, 2023. These applications are hereby incorporated by reference in their entirety.

[0002] (Technical Field) This disclosure relates to the field of electrical transmission lines.

Background Art

[0003] A laminated overhang surface may cause performance degradation when using a tuner to support the center conductor of an electrical transmission line. Examples of such performance degradation include electrical loss, higher-order mode propagation, and signal reflection.

Summary of the Invention

[0004] A laminated electrical transmission line is configured such that surface treatment is possible even on the inner surface after formation.

[0005] According to one aspect of this disclosure, an electrical transmission line includes an outer housing that defines a cavity therein, a conductive stripline that passes through the cavity, and a stub within the cavity that electrically couples the outer housing to the stripline, wherein the outer housing, the stripline, and the stub are all components of a single, unitary, continuous, monolithic, laminated transmission line.

[0006] According to embodiments of any of the paragraphs of this summary, the stub is disposed at an acute angle with respect to the direction in which the conductive stripline extends.

[0007] According to embodiments of any of the paragraphs of this summary, the stripline is flat.

[0008] According to any one or more embodiments of this summary, the stripline has a rectangular cross-section.

[0009] According to any one or more embodiments of this summary, the transmission line end of the stripline has a circular cross-section, and a transition region is provided between the rectangular cross-section and the transmission line end.

[0010] According to any one or more embodiments of this summary, the stripline has transmission line ends at both ends of the stripline.

[0011] According to any one or more embodiments of this summary, the outer housing narrows around the transmission line end, defining a constricted passage that fluidly communicates with the cavity.

[0012] According to any one or more embodiments of this summary, the stub has an angle of 30 to 60 degrees with respect to the stripline.

[0013] According to any one or more embodiments of this summary, the stub is at an angle of 40 to 50 degrees with respect to the stripline.

[0014] According to the embodiments of any paragraph(s) of this summary, the stub extends from both opposite ends of the stripline.

[0015] According to the embodiment of any one paragraph(s) of this summary, the stubs are arranged longitudinally along the stripline such that opposite sides are alternately offset from each other.

[0016] According to any one or more embodiments of this summary, the stub has convex, opposing, streamlined surfaces that facilitate flow through the stub.

[0017] According to any one or more embodiments of this summary, the air in the cavity acts as a dielectric around the stripline.

[0018] According to any one or more embodiments of this summary, the electrical transmission line is non-linear.

[0019] According to any one or more embodiments of this summary, the electrical transmission line (or part thereof) is a connector.

[0020] According to any one or more embodiments of this summary, an electrical transmission line (or part thereof) is a cable.

[0021] According to another aspect of the present disclosure, an electrical installation between a pair of devices includes an electrical conductor that couples a conductor of one device with a conductor of the other device, each electrical conductor including an outer housing that defines a cavity inside, a conductive stripline passing through the cavity, and a stub in the cavity that electrically couples the outer housing to the stripline, the outer housing, the stripline, and the stub all being components of a single, unified, continuous, monolithic, additively fabricated transmission line, and at least some of the electrical conductors being non-linear.

[0022] A method for manufacturing an electrical transmission line, comprising laminating an electrical conductor as a single molded product, wherein the electrical conductor comprises an outer housing defining a cavity inside, a conductive stripline passing through the cavity, and a stub electrically coupling the outer housing to the stripline; and treating the inner surfaces of the outer housing, the conductive stripline, and the stub to reduce surface roughness.

[0023] According to any one or more embodiments of this summary, additive manufacturing includes powder bed fusion.

[0024] According to any one or more embodiments of this summary, additive manufacturing includes laser powder bed fusion.

[0025] According to embodiments of any of the paragraphs (singly or in plurality) of this summary, additive manufacturing includes forming an electrical conductor longitudinally.

[0026] According to embodiments of any of the paragraphs (singly or in plurality) of this summary, the processing includes abrasive flow machining of the inner surface.

[0027] According to embodiments of any of the paragraphs (singly or in plurality) of this summary, abrasive flow machining includes reciprocating a fluid containing an abrasive within a cavity.

[0028] Regarding embodiments of the present disclosure, although several features are described herein, the features described for a given embodiment may also be used in relation to other embodiments. The following description and the accompanying set of drawings disclose specific exemplary embodiments of the present disclosure. However, these embodiments illustrate only a few examples of the various ways in which the principles of the present disclosure may be used. Other objects, advantages, and novel features according to aspects of the present disclosure will become apparent from the following detailed description when considered in conjunction with the drawings.

[0029] The accompanying drawings, which are not necessarily to scale, illustrate various aspects of the present disclosure.

Brief Description of the Drawings

[0030] [Figure 1] A perspective view of an electrical transmission line according to an embodiment. [Figure 2] A cross-sectional view of the electrical transmission line of FIG. 1. [Figure 3] A side-sectional view of the electrical transmission line of FIG. 1. [Figure 4] A cross-sectional view of a stub that can be used in the electrical transmission line of FIG. 1. [Figure 5] A perspective view of electrical transmission lines of various configurations, including non-linear (or curved, or inclined) electrical transmission lines. [Figure 6] An electrical facility is shown that electrically connects the electrical conductors of two devices using an electrical coupler. [Figure 7]This is a rough flowchart of the manufacturing method for electrical transmission lines. [Figure 8] This is a cross-sectional view of an electrical transmission line of a distributor / combiner, which is another embodiment. [Figure 9] This is yet another embodiment, a cross-sectional view of an electrical transmission line with a jumper having rectangular ends. [Figure 10] This is a cross-sectional view of an electrical transmission line of a curved transmission line having an extended end, which is yet another embodiment. [Modes for carrying out the invention]

[0031] An additively fabricated electrical transmission line is formed as a single, unified, continuous, monolithic additively fabricated material part and includes an outer housing that defines a cavity inside, a conductive stripline passing through the cavity, and a stub in the cavity that electrically connects the outer housing to the stripline. The stripline may be a flat stripline. The stub may be angled with respect to the stripline, which facilitates surface treatment within the housing (e.g., polishing to reduce surface roughness), and this may be part of the manufacturing method of the electrical transmission line. The electrical transmission line may be part of an electrical installation comprising a plurality of such electrical transmission lines, which may have various shapes, including curved shapes, to establish desired electrical connections between components.

[0032] Figures 1-3 show an electrical transmission line (or interconnection) 10 for electrically connecting multiple devices (not shown) to each other. The illustrated embodiment is a transmission line compatible with the corresponding connector, but many other electrical transmission line configurations are possible. The electrical transmission line 10 may be a cable or a part of a cable (e.g., with connectors at both ends). Alternatively, the electrical transmission line 10 may be a connector or a part of a connector.

[0033] The electrical transmission line 10 is a one-piece, additively manufactured product. The electrical transmission line 10 includes a housing 12, which encloses and defines a central cavity 14 within its interior. A stripline 16 penetrates the cavity 14 from the first end 22 of the transmission line 10 to the opposite (second) end 24 of the transmission line 10. The stripline 16 is electrically (and physically) connected to the housing 12 by a series of stubs 26 that extend between the stripline 16 and the housing 12 within the cavity 14.

[0034] The illustrated embodiments of the electrical transmission line 10 shown in Figures 1-3 are described in detail below. It should be understood that many alternative configurations are possible for the components described in more detail below.

[0035] The housing 12 may have a wider central section 28 and narrower ends 32 and 34. The central section 28 may be rectangular, and the ends 32 and 34 may have a circular cross-section. Transition sections 36 and 38 may be present between the various shapes of the central section 28 and the respective ends 32 and 34.

[0036] The cavity 14 has a wider central region 40 and narrower end regions 42 and 44, with tapered transition regions 46 and 48 between the central region 40 and the respective end regions 42 and 44. The central region 40 may have a rectangular shape enclosed by the flat inner wall of the central part 28 of the housing, and the end regions 42 and 44 may be enclosed by the rounded inner walls of the housing ends 32 and 34. The transition regions 46 and 48 of the cavity 14 are defined by curved housing interior surfaces located between the flat wall of the central region 40 and the end regions 42 and 44. This facilitates the flow of fluid material through the cavity 14 for post-forming surface treatments that reduce the roughness of the inner surface of the housing 12 defining the cavity 14. The end regions 42 and 44 may be narrowed annular passages that are fluidly connected to the central region 40.

[0037] The stripline 16 includes a flat central section 50 and circular ends 52 and 54. The transition regions 56 and 58 gradually change the shape of the stripline from the flat central section 50 and the stripline ends 52 and 54, which have a rectangular cross-section.

[0038] The stub 26 has a serrated pattern and extends from the alternating sides of the stripline center 50 to the inner wall of the housing center 28 (when viewed from a longitudinal perspective along the stripline 16). The stub 26 provides physical and electrical connections between the stripline 16 and the housing 12. The stub 26 is angled with respect to the stripline center 50. This inclination allows abrasive material to flow more easily through the cavity 14, for example, to reduce surface roughness after the formation of the electrical transmission line 10.

[0039] The stub 26 may be positioned at an angle of approximately 45 degrees with respect to the longitudinal direction of the stripline center 50. More broadly, the stub 26 may be positioned at an angle of 40 to 50 degrees, or 30 to 60 degrees, with respect to the longitudinal direction of the stripline 16.

[0040] The stub 26 may have a rectangular cross-sectional shape. Alternatively, as will be described in detail below, the stub 26 may have a cross-sectional shape that facilitates the flow of the abrasive fluid material through it, such as a tapered shape that is thicker in the center and thinner at the ends.

[0041] The stub 26 provides a short-circuit connection between the stripline 16 and the housing 12. The stub 26, in combination with the air-filled (dielectric) space around the stripline 16, can achieve desired electrical performance in the electrical transmission line 10. For example, this configuration can achieve desirable isolation from radio frequency (RF) interference. Alternatively, or additionally, the space around the stripline 16 may be filled with other dielectric materials (e.g., suitable powder, liquid, or resin).

[0042] The electrical transmission line 10 can be manufactured from any of the following suitable materials. Examples of suitable conductive materials include metals such as aluminum or titanium; metal alloys such as aluminum-based alloys, e.g., A205, and nickel-based alloys sold under the trademark of INCONEL; and metal-coated polymers.

[0043] The electrical transmission line 10 can be manufactured by an additive manufacturing process, such as by powder bed fusion. In such a method, selective heating, such as a laser or electron beam, is used to melt (sinter) a portion of the powder material layer, and the electrical transmission line 10 is formed by stacking layers. The electrical transmission line 10 may be stacked vertically, such as in the longitudinal direction along the stripline 16.

[0044] After the additive manufacturing process of the electrical transmission line 10, the transmission line 10 may be subjected to a process to improve its finish. This may include abrasive fluid processing, in which an abrasive fluid (fluid containing abrasive particles) is passed through the cavity 14 in one direction or in both directions (from end 22 to end 24 and / or from end 24 to end 22), possibly multiple times, in order to obtain a smoother finish on the inner surface of the electrical transmission line 10.

[0045] The electrical transmission line 10 offers several advantages. The parallel central conductor (stripline 16) and the grounding wall of the housing 12 enable easy vertical printing (additive manufacturing). The rectangular cross-section transmission line avoids downward-facing surfaces and thin-walled structures. The angled configuration of the stub 26 allows for easy printing and minimizes problems caused by partial sintering.

[0046] In the configuration of the electrical transmission line 10, the arrowhead pattern of the stub 26 conforms to additive manufacturing guidelines. Furthermore, the possibility of partial sintering of the powder on the downward-facing surface is minimized. By avoiding partial sintering of the powder, the possibility of foreign object damage (FOD) caused by such partially sintered powder is reduced. Surface finish can be improved without requiring complex post-machining processes.

[0047] Numerous configuration variations are possible. For example, the number and configuration of the stubs 26 can be changed to achieve the desired broadband performance in the electrical transmission line 10. The stubs 26 also have the advantage of providing a robust structural and thermal arrangement for the components of the electrical transmission line 10. Therefore, a high-temperature transmission line can be formed.

[0048] Figure 4 shows an example of the cross-sectional shape of a stub 126 that can be used as a substitute for stub 26 (Figure 2). Stub 126 has an uneven thickness, with its central portion 130 being thicker than its ends 132 and 134, and has a convex curved upper surface 136 and lower surface 138. The cross-sectional shape of stub 126 facilitates the movement of fluids such as polishing fluid through stub 126 during the polishing flow machining process. Advantageously, stub 126 may have low drag and / or facilitate exposure to the polishing fluid.

[0049] Figure 5 shows an example of the straight electrical transmission line 10 described above, and examples of inclined electrical transmission lines 212, 214, 216, 218, and 220 with various curvatures. The transmission lines 212-220 have a similar internal structure to the electrical transmission line 10 (Figure 2), but can be configured in any of the various suitable shapes, for example, to connect conductors of unaligned devices.

[0050] Figure 6 shows an electrical installation 300 that electrically connects a pair of devices 302 and 304 using a series of electrical transmission lines 310. The electrical transmission lines 310 may have a configuration similar to the electrical transmission lines 10 (Figures 1-3) and 212-220 (Figure 5) described above. The overall shape of the electrical transmission lines 310 may be configured to allow connection between aligned or offset conductors 312 and 314 of devices 302 and 304. The transmission lines 310 may be straight or curved as needed to link devices 302 and 304. The use of electrical transmission lines 310 can be an alternative to the use of flexible wires or cables, which allows for efficient arrangement of connections and is expected to improve performance, such as more effectively avoiding electrical interference at the connections. Advantages may include improved signal integrity, reduced loss, simplified assembly, and / or cost reduction.

[0051] Figure 7 shows a rough flowchart of method 400 for manufacturing the electrical transmission lines described above, such as the electrical transmission lines 10 (Figures 1-3) and 212-220 (Figure 5). In step 402, the electrical transmission line is additively molded as a single molded product including a housing, conductive stripline, and stub. Additive manufacturing may include powder bed fusion, such as laser powder bed fusion. In step 404, the surface of the electrical transmission line is treated to reduce surface roughness. Surface treatment may include polishing the inner surface of the electrical transmission line.

[0052] Figures 8-10 show examples of other possible transmission line configurations having various ends. Details relating to the embodiments shown in Figures 8-10 may be the same as those described above. Furthermore, details of the various embodiments can be combined with each other. For example, the ends of the various embodiments described herein can be combined with the shapes of any of the embodiments. Also, the dielectric material (air, solid, powder, or liquid) in the various embodiments can be used in other embodiments as well.

[0053] Figure 8 shows a transmission line 510 of a distributor / combiner having three branches 502, 504, and 506. The cavity 514 between the stripline 516 and the housing 512 may be filled (in whole or in part) with epoxy resin.

[0054] Figure 9 shows a U-shaped jumper transmission line 610. The cavity 614 between the stripline 616 and the housing 612 may be filled (in whole or in part) with dielectric powder, such as polytetrafluoroethylene (PTFE) powder. The ends 622 and 624 of the stripline 616 may have a rectangular cross-sectional shape.

[0055] Figure 10 shows a curved transmission line 710 with a 45-degree bend. Many other angles are possible as alternatives. The cavity 714 between the stripline 716 and the housing 712 may be filled (in whole or in part) with a dielectric liquid, such as an ionic liquid. The ends 722 and 724 of the stripline 716 extend outside the housing 712.

[0056] While this disclosure has illustrated and described in relation to one or more specific embodiments, equivalent changes and modifications will be recalled by those skilled in the art upon reading and understanding this specification and the accompanying drawings. Specifically, with respect to the various functions performed by the aforementioned elements (components, assemblies, devices, compositions, etc.), the terms used to describe such elements (including references to “means”) are intended, unless otherwise indicated, to correspond to any element that performs a particular function of the described element (i.e., is functionally equivalent), even if it is not structurally equivalent to the structure of the disclosure performing the function in one or more exemplary embodiments of the disclosure shown herein. Furthermore, while certain features of the disclosure may have been described in relation to only one or more of the several shown embodiments, such features may be combined with one or more other features of other embodiments so as to be desirable and advantageous in any given or particular application.

Claims

1. An outer housing that defines the cavity inside, A conductive strip line passing through the cavity, The outer housing comprises a stub in the cavity that electrically connects to the conductive stripline, The outer housing, the conductive stripline, and the stub are all components of a single, unified, continuous, monolithic, additively fabricated transmission line. The stub extends from both opposite ends of the conductive stripline, The stubs are arranged in the longitudinal direction along the conductive stripline such that the opposite sides are alternately offset from each other. Electrical transmission line.

2. The electrical transmission line according to claim 1, wherein the stub is angled to form an acute angle with respect to the direction in which the conductive stripline extends.

3. The electrical transmission line according to claim 1, wherein the conductive stripline is flat.

4. The electrical transmission line according to claim 1, wherein the conductive stripline has a rectangular cross-section.

5. The electrical transmission line according to claim 4, wherein the transmission line end of the conductive stripline has a circular cross-section, and a transition region is provided between the rectangular cross-section and the transmission line end.

6. The conductive stripline has transmission line ends at both ends of the conductive stripline, The electrical transmission line according to claim 1, wherein the outer housing narrows around the end of the transmission line, defining a constricted passage that fluidly communicates with the cavity.

7. The electrical transmission line according to claim 1, wherein the stub is at an angle of 30 to 60 degrees with respect to the conductive stripline.

8. The electrical transmission line according to claim 1, wherein the stub is at an angle of 40 to 50 degrees with respect to the conductive stripline.

9. The electrical transmission line according to claim 1, wherein the stub has convex, opposing streamlined surfaces that facilitate the flow through the stub.

10. The electrical transmission line according to claim 1, wherein the air in the cavity functions as a dielectric around the conductive stripline.

11. The electrical transmission line according to claim 1, wherein the electrical transmission line is non-linear.

12. An electrical installation between a pair of devices, The device comprises an electrical conductor that connects one conductor of the device to the other conductor of the device, and each of the electrical conductors is An outer housing that defines the cavity inside, A conductive strip line passing through the cavity, The outer housing comprises a stub in the cavity that electrically connects to the conductive stripline, The outer housing, the conductive stripline, and the stub are all components of a single, unified, continuous, monolithic, additively fabricated transmission line. At least a portion of the aforementioned electrical conductor is a non-linear electrical conductor, The stub extends from both opposite ends of the conductive stripline, The stubs are arranged in the longitudinal direction along the conductive stripline such that the opposite sides are alternately offset from each other. Electrical equipment.

13. A method for manufacturing an electrical transmission line, The method involves laminating an electrical conductor as an integrally molded product, wherein the electrical conductor is An outer housing that defines the cavity inside, A conductive strip line passing through the cavity, The outer housing includes a stub that electrically connects to the conductive stripline, the stub extending from opposite ends of the conductive stripline, and the stubs being arranged longitudinally along the conductive stripline such that the opposite ends are alternately offset from each other. The aforementioned lamination formation, To reduce surface roughness, the inner surfaces of the outer housing, the conductive stripline, and the stub are treated, method.

14. The method according to claim 13, wherein the lamination formation includes powder bed molding.

15. The method according to claim 13, wherein the lamination formation includes laser powder bed fabrication.

16. The method according to claim 13, wherein the lamination formation includes forming the electrical conductor in the longitudinal direction.

17. The method according to claim 13, wherein the process includes polishing the inner surface.

18. The method according to claim 17, wherein the abrasive flow machining includes reciprocating a fluid containing an abrasive material within the cavity.

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