Dielectric Waveguide Injection Molding Sub-Millimeter Loss

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Solution Overview

Problem

The fabrication of small dimension metallic waveguides for sub-millimeter/terahertz frequency applications is challenging due to their inflexibility and high manufacturing costs, and existing dielectric waveguides do not adequately meet single-mode and modal-operation conditions.

Innovation Solution

A dielectric waveguide with polymeric materials, such as thermoplastics like polyethylene or polypropylene, is fabricated using injection molding, featuring tapered dielectric probes at each end to facilitate energy transfer and operate effectively at sub-millimeter/terahertz frequencies with low propagation loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If metallic waveguides are used for sub-millimeter/terahertz frequency applications, then single-mode and modal-operation conditions can be satisfied, but manufacturing cost increases and fabrication becomes challenging

Engineering Contradiction:

Improvesingle-mode operationVSAvoidfabrication difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive metallic waveguides with inexpensive dielectric waveguides made from materials like polyethylene and polypropylene. These dielectric waveguides can be mass-produced using injection molding, dramatically reducing manufacturing cost while maintaining functional performance for sub-millimeter/terahertz applications.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the material parameter from metal to dielectric materials, fundamentally altering the waveguide's electromagnetic properties. This parameter change enables single-mode operation at sub-millimeter/terahertz frequencies while allowing for cost-effective fabrication through plastic injection molding processes.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If metallic waveguides are used for sub-millimeter/terahertz frequency applications, then single-mode and modal-operation conditions can be satisfied, but manufacturing cost increases

Engineering Contradiction:

Improvesingle-mode operationVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent substitutes the mechanical fabrication process of metallic waveguides (requiring precision machining) with a polymer injection molding process. This substitution enables high-volume production at low cost, as injection molding is inherently suited for mass production of complex geometries without tooling wear or material waste.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If dielectric waveguides are used, then manufacturing cost decreases and flexibility increases, but propagation loss increases

Engineering Contradiction:

Improvemanufacturing costVSAvoidpropagation loss

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent optimizes the dielectric constant and loss tangent parameters of the polymeric materials to minimize propagation loss. By carefully selecting and formulating polyethylene and polypropylene materials with specific electromagnetic properties, the waveguide achieves low propagation loss while maintaining the cost and flexibility advantages of dielectric construction.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If small dimension waveguides are fabricated for sub-millimeter/terahertz applications, then single-mode and modal-operation conditions are satisfied, but fabrication becomes particularly challenging

Engineering Contradiction:

Improvemodal operationVSAvoidfabrication precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent substitutes the mechanical fabrication process of metallic waveguides (requiring precision machining) with a polymer injection molding process. This substitution enables high-volume production of small-dimension waveguides at low cost, as injection molding inherently provides excellent dimensional control and repeatability for miniaturized structures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs tapered dielectric probes with gradually changing cross-sectional dimensions to facilitate smooth mode transitions and minimize reflections. The tapered geometry, achievable through injection molding, gradually transforms the electromagnetic mode from the waveguide to free space, reducing impedance discontinuities and improving measurement accuracy.

Inventive Principle:

Principle #32Color changes

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 solution enables the production of flexible, low-cost dielectric waveguides with propagation loss less than 0.5 dB/cm, suitable for sub-millimeter/terahertz frequencies, and allows for mass production with potential for new functionalities in waveguide circuits.

Implementation Method 1

dielectric waveguides have been used in transmission line applications, as well as in waveguide circuits to confine, process and transmit light over various distances

Methodology Applied

Scientific EffectElectromagnetic wave propagation: Electromagnetic Induction