Corrugated Waveguide Structure for Support-Free 3D Printing
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Solution Overview
Problem
Conventional manufacturing methods struggle to produce corrugated waveguide filters efficiently due to their complex shape, leading to issues like sagging cantilevered parts during additive manufacturing, requiring tedious reinforcement and slowing down the process.
Innovation Solution
A corrugated passive radio frequency device with inclined adjacent walls forming cavities or grooves relative to the central axis, reducing stress on overhanging surfaces and eliminating the need for supports during additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional active electronic devices are used for wireless communication, then communication functionality is achieved, but device complexity and biocompatibility issues arise
Solution Approach 1:
The patent replaces active electronic communication devices with a passive radiofrequency device that uses electromagnetic field modulation through mechanical or physical means (such as reconfigurable antenna elements or resonant structures). This substitution eliminates complex electronics while maintaining wireless communication capability through passive electromagnetic interaction.
Solution Approach 2:
The patent employs a passive radiofrequency device that can be disposed of after use, eliminating the need for complex power management and electronic components. The device is designed to be simple, low-cost, and suitable for single-use applications, thereby reducing device complexity while maintaining communication functionality during its operational lifetime.
2Ease of manufacture
If conventional manufacturing methods are used, then device fabrication is achieved, but manufacturing precision and structural complexity increase
Solution Approach 1:
The patent utilizes additive manufacturing parameters and material properties to achieve precise corrugated structures with relaxed tolerances. By optimizing printing parameters, layer thickness, and material selection, the invention achieves the required structural precision through process control rather than post-manufacturing adjustments, thereby improving ease of manufacture.
Solution Approach 2:
The patent divides the device into modular components that can be manufactured separately and assembled, or printed in sections. This segmentation allows each component to be optimized for manufacturing while maintaining overall structural integrity, reducing the cumulative effect of manufacturing tolerances and improving ease of manufacture.
3Ease of manufacture
If planar structures are used, then manufacturing is simplified, but antenna performance and signal propagation are degraded
Solution Approach 1:
The patent employs corrugated (curved/wavy) structures instead of planar geometries to improve antenna performance. The curved surfaces enhance signal propagation characteristics, impedance matching, and radiation patterns while maintaining compatibility with additive manufacturing processes, thereby achieving both good performance and ease of manufacture.
Solution Approach 2:
The patent transitions from two-dimensional planar structures to three-dimensional corrugated structures by adding vertical dimensionality through layer-by-layer additive manufacturing. This dimensional transition improves antenna performance through enhanced electromagnetic field distribution and radiation characteristics while leveraging the inherent capability of 3D printing to create complex geometries.
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
Facilitates the additive manufacturing of corrugated waveguides by minimizing stress on cantilevered parts, allowing for faster and more controlled production without the need for additional reinforcements.
Implementation Method 1
a three-dimensional (3D) corrugated passive radiofrequency (RF) device that is suitable for an additive manufacturing method
Data Source
Figure 1~3
Figure 4~5
Figure 6~7c
AI summary
The invention relates to a corrugated passive radiofrequency device (1), notably a waveguide or an antenna of the horn type. The device (1) comprises a core (2) comprising at least one internal face (4, 5, 6, 7; 12) delimiting a canal (3) for filtering and guiding the waves. The at least one internal face (4, 5, 6, 7; 12) of the canal comprises a plurality of cavities (9) or of grooves (10). Each cavity (9) or each groove (10) is formed by adjacent walls (11a, 11b) that are substantially parallel in order to filter the waves passing along the canal. The adjacent walls (11a, 11b) are inclined with respect to the central axis of the canal (3).