Axially Stacked RF Rotary Coupler Reducing Housing Diameter
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Solution Overview
Problem
Existing radio frequency (RF) rotary couplers require large housing diameters due to radial construction of corporate feed assemblies, leading to increased size and weight in applications like aircraft and space-borne equipment, where compactness is crucial.
Innovation Solution
Implementing a linear corporate feed approach with axially stacked and interconnected power divider layers, reducing the outside diameter and minimizing axial length, allowing for smaller packaging of multiple channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If radial construction of corporate feed assemblies is used, then RF energy can be transmitted between stator and rotor, but housing diameter increases significantly
Solution Approach 1:
The patent transitions from a radial arrangement of power feeds to an axial arrangement by stacking circuit layers vertically. The power dividers are organized in multiple axial layers with feeds extending along the axial direction rather than radially outward, fundamentally changing the spatial dimension of the feed assembly and reducing the required housing diameter by at least 55%.
Solution Approach 2:
The patent implements nested circuit layers where multiple power divider layers are stacked axially within the stator and rotor assemblies. Each layer contains power dividers and feeds that are integrated into the cylindrical structure, with inner layers nested within the overall assembly. This nested configuration allows multiple feed paths to coexist in a compact axial footprint, reducing the housing diameter while maintaining all necessary RF transmission paths.
2Adaptability or versatility
If number of power feeds doubles with each additional circuit path, then multichannel capability is achieved, but device complexity increases
Solution Approach 1:
The patent segments the corporate feed assembly into multiple discrete circuit layers, with each layer containing a specific number of power dividers and feeds. The first circuit layer has a first number of power dividers, the second circuit layer has a second number of power dividers, and so on. This segmentation allows systematic organization of multiple feed paths and simplifies the integration of additional channels by adding more axial layers rather than complicating the radial arrangement.
Solution Approach 2:
The patent resolves the complexity issue by organizing power feeds in the axial dimension rather than radially. Multiple circuit layers are stacked along the axial direction, with each layer handling a subset of the total feed paths. This dimensional reorganization allows the system to scale to multiple channels by simply adding more axial layers, making the complexity management more systematic and manageable compared to the exponential growth required in radial configurations.
3Ease of manufacture
If coaxial cables are run up the axis to connect stacked channels, then through-hole size must increase, but cable routing becomes simpler
Solution Approach 1:
The patent nests multiple coaxial cable paths within the axial structure by routing cables through the central through-hole in a bundled configuration. The nested circuit layers are positioned such that their feeds converge toward the central axis, allowing multiple cables to be routed together through a single or minimized number of through-holes. This nesting approach simplifies cable routing while maintaining a compact through-hole size compared to radial cable exits that would require multiple large openings.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration significantly reduces the housing diameter by at least 55% and occupies only 30% of the original cylindrical area, addressing size and weight concerns in compact applications.
Implementation Method 1
the energy may be fed onto a dynamic capacitive ring within a matched RF cavity (the dynamic capacitive ring is the section of the rotary joint that allows it to turn and also pass RF energy across the rotating section)
Data Source
AI summary
A radio frequency rotary coupler with its power dividers/couplers separated among multiple circuit layers that are axially stacked and interconnected using coaxial feeds. This architecture allows for multiple layers of circuits with minimal outside diameter and while minimizing increase in axial length. The coupler includes a stator, rotor, and dynamic capacitive ring. The stator includes at least a first stator circuit layer with a primary stator power divider (SPD), a second stator circuit layer with at least one secondary SPD, and stator coaxial feeds coupling the primary SPD and the secondary SPD(s). The rotor includes a first rotor circuit layer with a primary rotor power divider (RPD), a second rotor circuit layer with at least one secondary RPD, and rotor coaxial feeds coupling the primary RPD and the secondary RPD(s). The dynamic capacitive ring couples the stator and the rotor via the secondary SPD(s) and RPD(s).