Flexible Waveguide Mounting for Stress-Relieved Flange Connections

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Solution Overview

Problem

Waveguides with flexible sections face risks of mechanical damage and impairment of signal transmission properties due to high mechanical loads and relative movements between flanges and the waveguide section, leading to potential damage at connection points.

Innovation Solution

A waveguide design featuring a flexible waveguide section with a lamellar structure and a fastening unit that engages with recesses on the surface, absorbing mechanical loads and preventing relative movement between the waveguide section and flanges, thereby relieving mechanical stress from the electrical connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the electrical/mechanical connection between the waveguide section and flanges is designed to be mechanically strong, then mechanical strength is improved, but structural damage may still adversely affect signal transmission properties

Engineering Contradiction:

Improvemechanical strength of connectionVSAvoidsignal transmission quality

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The connection system is divided into two separate functional units: an electrical connection element for signal transmission and a mechanical fastening unit for structural support. This segmentation allows each element to be optimized for its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fastening unit acts as an intermediary that mechanically couples the waveguide section to the flange while preventing direct transmission of mechanical stresses to the electrical connection. The fastening unit absorbs and distributes mechanical loads, protecting the delicate electrical connection from damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the waveguide section is made flexible to allow tolerance compensation and absorb thermomechanical loads, then adaptability is improved, but the connection point becomes vulnerable to mechanical damage

Engineering Contradiction:

Improvemechanical flexibilityVSAvoidconnection durability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The waveguide assembly is segmented into a flexible waveguide section and a rigid flange section, connected through separate electrical and mechanical coupling elements. This allows the flexible section to accommodate movements while the rigid flange maintains stable connections.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fastening unit is designed to anticipate and absorb mechanical stresses before they can reach the electrical connection. By providing mechanical support and stress distribution in advance, the system protects the connection point from potential damage during flexible deformation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Adaptability or versatility

If relative movements between flanges and waveguide section are allowed to accommodate thermal expansion, then adaptability is improved, but recurring movements increase risk of connection damage

Engineering Contradiction:

Improvethermal expansion compensationVSAvoidconnection stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The connection system separates electrical and mechanical functions into distinct elements, allowing the mechanical fastening unit to handle thermal expansion movements while the electrical connection remains protected from mechanical stresses.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fastening unit serves as a mediator that allows controlled relative movements for thermal compensation while preventing damaging movements from reaching the electrical connection. It mediates between the need for flexibility and the need for connection stability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4421977A1Hollow conductor with a flexible hollow conductor section and mechanical relief of a connection point

Publication Date: 2024.08.28 TESAT SPACECOM GMBH & CO KG

Figure 1~2
Figure 3~4

AI summary

A waveguide (100) comprises a first flange (110), a second flange (120), a flexible waveguide section (130), and a first mounting unit (140). The flexible waveguide section (130) is electrically connected to both the first flange (110) and the second flange (120) such that a high-frequency signal (HF signal) can be transmitted from the first flange (110) to the second flange (120) or vice versa via the flexible waveguide section (130). The flexible waveguide section (130) has a surface (131), and a first recess (132) is arranged in the surface (131). The first mounting unit (140) is connected to the first flange (110).The first fastening unit (140) lies in a first overlap area (141) in a longitudinal direction (135) of the flexible waveguide section (130) on the surface (131) of the flexible waveguide section (130) and engages in the first recess (132) of the flexible waveguide section (130) and fixes the flexible waveguide section (130) with respect to the first flange (110).