Apertured Metal Waveguides for Weight Reduction
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Solution Overview
Problem
Metal waveguides used in high-power applications are heavy and require significant material due to their solid construction, and electroless-plated, three-dimensional printed plastic parts suffer from low power capability and delamination issues, as well as higher loss compared to solid metal waveguides.
Innovation Solution
The use of apertured metal waveguides with a plurality of apertures in their walls to reduce material and weight while maintaining low loss characteristics, constructed using additive manufacturing processes such as metal binder jetting, which allows for the creation of lightweight, high-power, low-loss waveguides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If solid metal waveguides are used for high-power applications, then power capability and low loss are improved, but weight and material quantity increase significantly
Solution Approach 1:
The waveguide walls are constructed with a porous or apertured structure containing multiple holes or voids. This porous configuration reduces the amount of metal material required, thereby decreasing weight while maintaining the waveguide's electromagnetic wave transmission capabilities and power handling characteristics.
Solution Approach 2:
The waveguide employs a composite structure combining metal walls with apertures or porous sections. This composite design integrates the advantages of solid metal (low loss, high power capability) with the weight reduction benefits of reduced material quantity, creating an optimized structure for high-power applications.
2Power
If solid metal waveguides are used for high-power applications, then power capability and low loss are improved, but the amount of material required increases
Solution Approach 1:
The waveguide walls are constructed with a porous or apertured structure containing multiple holes or voids. This porous configuration reduces the amount of metal material required, thereby decreasing weight while maintaining the waveguide's electromagnetic wave transmission capabilities and power handling characteristics.
Solution Approach 2:
The solid metal walls are segmented by introducing multiple apertures or holes throughout the waveguide structure. This segmentation removes unnecessary material while preserving the structural integrity and electromagnetic performance required for high-power operation, thus reducing material quantity without sacrificing power capability.
3Weight of stationary object
If electroless-plated, three-dimensional printed plastic parts are used, then weight is reduced, but power capability and structural integrity deteriorate due to low glass transition temperatures and delamination
Solution Approach 1:
The waveguide employs a composite structure combining metal walls with apertures or porous sections. This composite design integrates the advantages of solid metal (low loss, high power capability) with the weight reduction benefits of reduced material quantity, creating an optimized structure for high-power applications.
Solution Approach 2:
The waveguide walls are constructed with a porous or apertured structure containing multiple holes or voids. This porous configuration reduces the amount of metal material required, thereby decreasing weight while maintaining the waveguide's electromagnetic wave transmission capabilities and power handling characteristics.
Data Source
AI summary
In some embodiments, an apertured waveguide includes a wall comprising a plurality of apertures and an interior channel along which electromagnetic waves can propagate, the interior channel being defined at least in part by the wall.