Gap-Interface Waveguide Assembly for Alignment-Tolerant Coupling

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Waveguide-to-waveguide coupling in antenna systems faces challenges with alignment tolerance issues, leading to reflector distortions and inefficient signal transmission due to high precision requirements.

Innovation Solution

A waveguide assembly with a gap interface and a choke configuration allows for relative movement between waveguide portions while maintaining efficient signal transmission across a desired bandwidth, using a slip fit connection and a choke to prevent contact and minimize reflections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If waveguide portions are connected with a precision fit to ensure signal transmission, then signal transmission efficiency is improved, but alignment tolerance requirements increase and manufacturing complexity worsens

Engineering Contradiction:

Improvesignal transmission efficiencyVSAvoidalignment tolerance

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The waveguide connection is divided into two distinct portions: a fixed waveguide portion and a movable waveguide portion. This segmentation allows each portion to be optimized independently - the fixed portion provides stable signal transmission while the movable portion accommodates alignment variations, thereby maintaining signal efficiency without requiring high precision alignment between components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A gap interface is introduced as an intermediary element between the fixed and movable waveguide portions. This gap acts as a mediator that decouples the rigid alignment requirements, allowing electromagnetic signals to pass through while accommodating relative movement and misalignment between the two waveguide portions without compromising transmission efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If waveguide portions are rigidly connected to maintain alignment, then signal transmission stability is improved, but adaptability to axial movement decreases

Engineering Contradiction:

Improvealignment stabilityVSAvoidaxial movement range

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The connection between waveguide portions transitions from a rigid static joint to a dynamic configuration with a defined gap. This allows the movable waveguide portion to accommodate axial movements while maintaining stable signal transmission characteristics. The gap interface enables the system to adapt to position changes without losing alignment stability, as the electromagnetic field can tolerate the separation distance.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If a gap interface is used to allow movement between waveguide portions, then adaptability to alignment variations is improved, but signal transmission efficiency may deteriorate due to reflections

Engineering Contradiction:

Improvealignment toleranceVSAvoidsignal transmission efficiency

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The gap interface, which could potentially cause signal reflections and transmission losses, is converted into a beneficial feature by carefully controlling its dimensions and positioning. The gap is designed to be electrically small relative to the wavelength, transforming what would be a harmful discontinuity into an acceptable impedance transition that maintains signal integrity while enabling the necessary mechanical flexibility and alignment tolerance.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 efficient transmission of electromagnetic signals over a range of frequencies with reduced alignment tolerance requirements, preventing reflector distortions and maintaining performance even with axial movement, thus improving the robustness of waveguide assemblies.

Implementation Method 1

The combination of the gap and the choke configuration enables signals to be passed through the combined waveguide assembly with the appropriate bandwidth or range of frequencies desired

Methodology Applied

Scientific EffectElectromagnetic reflection: Reflection

Data Source

PatentUS11901599B1Waveguide assembly comprising first and second waveguide portions joined together through a gap interface and communication system formed therefrom

Publication Date: 2024.02.13 SPACE EXPLORATION TECHNOLOGIES CORP

AI summary

In one embodiment, a waveguide assembly includes a first waveguide portion having a first end, a second end, and a first waveguide channel extending between the first end and the second end, and a second waveguide portion having a first end, a second end, and a second waveguide channel extending between the first end and the second end, wherein the first waveguide portion and the second waveguide portion are configured to connect such that the first waveguide channel and the second waveguide channel form a combined channel, wherein the combined channel includes a gap interface between the first waveguide channel and the second waveguide channel.