Integrally Formed Waveguide Assembly for Compact RF Networks

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Solution Overview

Problem

Conventional waveguide assemblies for RF signals are complex and require significant spatial and weight penalties due to the need for multiple individual waveguides, which complicates system design and increases manufacturing time, especially in applications like satellite payloads with multiple beams.

Innovation Solution

The integration of multiple waveguides into a single, self-supporting assembly with optimized connector design and manufacturing using additive manufacturing, allowing for compact configurations and reduced mass, cost, and production time, while minimizing signal loss and maximizing packing density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple individual waveguides are used to accommodate complex signal paths, then signal routing flexibility is improved, but spatial footprint and weight increase

Engineering Contradiction:

Improvesignal routing flexibilityVSAvoidwaveguide assembly weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of stationary object

Solution Approach 1:

Multiple waveguides are merged into a single integrally formed waveguide assembly containing multiple waveguide bores within a common structure. This combining approach maintains the signal routing flexibility of multiple separate waveguides while dramatically reducing the overall weight and spatial footprint by eliminating redundant external support structures and flanges.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Multiple waveguide bores are nested within a single common wall structure, with each waveguide bore containing its internal surfaces while sharing the external support framework. This nesting arrangement allows complex signal paths to be accommodated within a compact volume, reducing both weight and spatial requirements compared to externally arranged separate waveguides.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Ease of manufacture

If multiple individual waveguides are used with separate flanges, then ease of assembly is improved, but manufacturing time and complexity increase

Engineering Contradiction:

Improveassembly easeVSAvoidmanufacturing speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

Multiple waveguides and their associated flanges are merged into a single integrally formed assembly, eliminating the need to manually assemble multiple separate flanged components. This approach maintains ease of manufacture through standardized integral formation processes while dramatically increasing productivity by reducing assembly steps and manufacturing time.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If waveguides are spaced out and arranged over many spatial layers, then signal path routing is improved, but spatial footprint increases

Engineering Contradiction:

Improvesignal path routingVSAvoidspatial footprint

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

Multiple waveguide bores are nested within a common wall structure, allowing complex three-dimensional signal paths to be routed through vertically stacked bores rather than horizontally spread out. This nesting arrangement maintains full signal routing flexibility while compressing the spatial footprint into a compact vertical arrangement.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The waveguide assembly utilizes vertical stacking of multiple waveguide bores within a common structure, transitioning from horizontal spatial distribution to vertical arrangement. This dimensional reorganization maintains signal path routing capabilities while dramatically reducing the horizontal spatial footprint.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Adaptability or versatility

If complex waveguide configurations are designed, then signal network capability is improved, but mechanical tolerance requirements increase

Engineering Contradiction:

Improvesignal network capabilityVSAvoidmechanical tolerance

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

Multiple waveguides are formed as a single integral structure, eliminating the need for precision mechanical assembly of multiple separate components. This approach maintains complex signal network capabilities while reducing manufacturing precision requirements by forming all waveguide bores and common walls in a single manufacturing process without requiring tight tolerances between assembled parts.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11469482B2Waveguide assembly having a plurality of waveguides connected by a flange integrally formed with at least three waveguide ports

Publication Date: 2022.10.11 AIRBUS DEFENCE AND SPACE LTD

AI summary

A waveguide assembly for a radio frequency (RF) signal network can include a plurality of waveguides, wherein at least two of the plurality of waveguides are integrally formed with each other. A satellite payload can include the waveguide assembly, a method of manufacturing a waveguide assembly, and a method of manufacturing a signal network. Also provided is a waveguide connector having a flange, and a plurality of ports, wherein the flange can couple to a further waveguide connector, each port of the plurality of ports being configured to interface with a respective waveguide.