Multi-Piece Corrugated Waveguide Using an Internal Coil Spring
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Solution Overview
Problem
Existing methods for forming corrugated waveguides are expensive and prone to manufacturing errors, leading to inefficient transmission of electromagnetic waves and high operational and maintenance costs due to the difficulty in producing long lengths with precise corrugation features.
Innovation Solution
A multi-piece corrugated waveguide design using a coil spring within a tube, where the coil spring forms the corrugation features, allowing for longer lengths without errors and enabling efficient electromagnetic wave propagation by optimizing the width, depth, and pitch of the coil springs for specific transmission modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If corrugated waveguides are formed in single lengths of tubes, then the waveguide structure is complete and functional, but manufacturing becomes expensive and prone to errors
Solution Approach 1:
The waveguide is divided into multiple separate tube sections that can be manufactured independently with standard corrugation techniques. Each section is then connected using coupling mechanisms (flanges, welds, or mechanical joints) to form the complete waveguide assembly. This segmentation allows each component to be manufactured with higher precision using conventional methods rather than attempting to create a single long corrugated tube.
2Loss of energy
If long lengths of corrugated waveguide are produced, then transmission efficiency is improved, but manufacturing errors increase and inventory waste occurs
Solution Approach 1:
The waveguide is divided into multiple separate tube sections that can be manufactured independently with standard corrugation techniques. Each section is then connected using coupling mechanisms (flanges, welds, or mechanical joints) to form the complete waveguide assembly. This segmentation allows each component to be manufactured with higher precision using conventional methods rather than attempting to create a single long corrugated tube.
Solution Approach 2:
The design allows for adjustment of corrugation parameters (depth, width, pitch) in different sections to optimize transmission efficiency for specific frequency ranges. By varying these parameters across multiple sections rather than maintaining uniform corrugations throughout a single long tube, the system achieves better overall transmission performance while maintaining manufacturing precision.
3Loss of energy
If specialized materials and equipment are used for corrugated waveguides, then transmission efficiency is enhanced, but operational and maintenance costs increase
Solution Approach 1:
The waveguide is divided into multiple separate tube sections that can be manufactured independently with standard corrugation techniques. Each section is then connected using coupling mechanisms (flanges, welds, or mechanical joints) to form the complete waveguide assembly. This segmentation allows each component to be manufactured with higher precision using conventional methods rather than attempting to create a single long corrugated tube.
Solution Approach 2:
The design allows for adjustment of corrugation parameters (depth, width, pitch) in different sections to optimize transmission efficiency for specific frequency ranges. By varying these parameters across multiple sections rather than maintaining uniform corrugations throughout a single long tube, the system achieves better overall transmission performance while maintaining manufacturing precision.
4Device complexity
If single-piece corrugated waveguides are deployed, then the structure is simple, but repair and replacement become difficult and time-consuming
Solution Approach 1:
The waveguide is divided into multiple separate tube sections that can be manufactured independently with standard corrugation techniques. Each section is then connected using coupling mechanisms (flanges, welds, or mechanical joints) to form the complete waveguide assembly. This segmentation allows each component to be manufactured with higher precision using conventional methods rather than attempting to create a single long corrugated tube.
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
This design reduces operational and maintenance costs by allowing for precise manufacturing of individual components, improving transmission efficiency, and enabling easy repair and replacement of coil springs, while minimizing errors and material waste.
Implementation Method 1
the coil spring and/or a cross-sectional profile of each coil element of the plurality of coil elements can be dimensioned to propagate an electromagnetic wave
Data Source
AI summary
An apparatus includes a tube including an inner surface, an inner diameter, and a length. The apparatus also includes a coil spring. The coil spring includes an outer surface, an outer diameter, and a plurality of coil elements arranged along a length of the coil spring. The coil spring can be positioned within the tube and the outer diameter of the coil spring can be less than the inner diameter of the tube. The coil spring can form a waveguide. Related methods of manufacture and systems are also described herein.