Coil Spring Corrugated Waveguide Assembly for Long-Length Precision
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Solution Overview
Problem
Existing methods for forming corrugated waveguides are costly, prone to manufacturing errors, and inefficient in transmitting electromagnetic waves, particularly for long lengths, due to residual materials and difficulty in coating and machining.
Innovation Solution
A multi-piece corrugated waveguide design that uses a coil spring arranged within a tube, where the coil spring provides the corrugation features and the tube offers structural support, allowing for longer waveguide lengths with reduced errors and improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If corrugated waveguides are formed in single lengths of tubes using traditional methods, then the waveguide structure is complete, but manufacturing costs are high, manufacturing errors occur, and residual materials remain
Solution Approach 1:
The waveguide is divided into two separate components: a tube and a coil spring. The coil spring is inserted into the tube to form the corrugated structure, eliminating the need to machine corrugations directly into a single tube. This segmentation allows each component to be manufactured separately with standard techniques, then assembled together, reducing manufacturing complexity and improving precision.
Solution Approach 2:
The coil spring is nested within the tube, with the spring's outer diameter being less than the tube's inner diameter. This nesting arrangement allows the corrugated structure to be formed by the spring inside the tube, avoiding the need for complex machining operations on the tube itself and eliminating residual materials from machining processes.
2Ease of manufacture
If traditional single-piece corrugated waveguides are used, then the structure is rigid, but coating and machining become difficult and costly
Solution Approach 1:
By separating the waveguide into a tube and a coil spring, the corrugated structure is formed by the spring rather than being machined into the tube. This eliminates difficult machining operations and allows the tube to be coated separately and more easily, reducing material waste from machining errors.
Solution Approach 2:
The coil spring acts as a flexible element that can be easily coated with conductive or protective materials. The spring's flexible nature allows for uniform coating application without the difficulties associated with coating rigid, pre-corrugated tubes, thereby reducing material waste and manufacturing costs.
3Length of moving object
If long-length single-piece waveguides are manufactured, then the transmission distance is sufficient, but manufacturing errors and residual materials increase
Solution Approach 1:
The waveguide is segmented into a tube and a coil spring that can be manufactured separately and then assembled. This allows long-length waveguides to be constructed by joining multiple tube-spring assemblies, maintaining manufacturing precision while achieving the required transmission distance and eliminating residual materials from single-piece machining.
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
The multi-piece corrugated waveguide design reduces manufacturing costs and errors, enhances the efficiency of electromagnetic wave transmission, and facilitates easier coating and maintenance compared to traditional methods.
Implementation Method 1
A waveguide is a structure that guides waves, such as electromagnetic waves or sound, with minimal loss of energy by restricting the transmission of energy to one direction
Implementation Method 2
The inner surface of the coil spring can include a conductive material
Data Source
AI summary
An apparatus includes a tube including an inner surface, an inner diameter, and a length. The apparatus also includes a coil spring. The coil spring includes an outer surface, an outer diameter, and a plurality of coil elements arranged along a length of the coil spring. The coil spring can be positioned within the tube and the outer diameter of the coil spring can be less than the inner diameter of the tube. The coil spring can form a waveguide. Related methods of manufacture and systems are also described herein.