Metal-Diamond Waveguide Housing With Precision Insert Coupling
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Solution Overview
Problem
Existing RF waveguide housings made from materials like copper molybdenum, copper tungsten, aluminum, and iron-nickel alloys have limited thermal conductivity, necessitating precise machining to match RF waveguide dimensions, which is inefficient and thermally inadequate for modern devices.
Innovation Solution
A metal-diamond composite-based RF waveguide housing with precisely machined inserts made from materials like CuMo, CuW, Al, or Kovar, coupled with a metal-diamond base providing high thermal conductivity, and ceramic feedthroughs to ensure hermetic sealing and RF energy transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional materials (copper molybdenum, copper tungsten, aluminum, iron-nickel alloys) are used for RF waveguide housing, then manufacturing is easier, but thermal conductivity is limited
Solution Approach 1:
The patent employs a metal-diamond composite material for the RF waveguide housing. This composite combines the high thermal conductivity of diamond with the mechanical properties and manufacturability of metal matrices, achieving superior thermal performance while maintaining ease of manufacturing through established composite fabrication techniques.
2Adaptability or versatility
If traditional materials are used for RF waveguide housing, then material availability is better, but thermal conductivity is insufficient for modern devices
Solution Approach 1:
The metal-diamond composite housing provides the high thermal conductivity required for modern devices while maintaining adaptability through various manufacturing approaches. The composite can be fabricated using techniques such as sintering, infiltration, or powder metallurgy, allowing flexibility in production while meeting advanced thermal requirements.
3Manufacturing precision
If precise machining is performed on traditional materials to match RF waveguide dimensions, then dimensional accuracy is achieved, but manufacturing efficiency decreases
Solution Approach 1:
The metal-diamond composite housing can be manufactured with precise dimensions through advanced composite fabrication techniques, reducing or eliminating the need for extensive post-manufacturing machining. This approach maintains dimensional accuracy while significantly improving manufacturing efficiency compared to traditional materials.
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 provides improved thermal conductivity and precise mating with RF waveguides while maintaining hermetic sealing and RF energy transmission, addressing the inefficiencies of previous materials.
Implementation Method 1
a metal-diamond base with a first surface and a second surface opposite the first surface. The metal-diamond base includes an opening through a thickness of the metal-diamond base
Implementation Method 2
ceramic feedthroughs to ensure hermetic sealing and RF energy transparency
Implementation Method 3
The insert defines an interior volume within the opening of the metal-diamond base and a shape of the insert at the first side of the opening is configured to match an end of an RF waveguide coupled to the RF waveguide housing
Data Source
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AI summary
A radio frequency (RF) waveguide housing includes a metal-diamond base with a first surface and a second surface opposite the first surface. The metal-diamond base includes an opening through a thickness of the metal-diamond base, and the opening includes a first side on a side of the first surface of the metal-diamond base and a second side on a side of the second surface of the metal-diamond base. The RF waveguide housing also includes an insert to be inserted in the opening and affixed to the metal-diamond base. The insert defines an interior volume within the opening of the metal-diamond base and a shape of the insert at the first side of the opening is configured to match an end of an RF waveguide coupled to the RF waveguide housing.