Nested Waveguide Assembly for Precise Variable THz Length
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing waveguides face challenges in achieving precise and variable lengths, particularly at frequencies above 100 GHz, due to manufacturing tolerances and limitations in substrate thickness, which affect mechanical precision and electrical performance.
Innovation Solution
A variable length vertically stacked nested waveguide device comprising a series of waveguide components with aligned openings, each with a recess and conductive coating, forming a nested structure that allows for precise control of combined waveguide length through precise production and alignment of individual components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If through-going apertures are used in substrate material, then waveguide manufacturing is simplified, but manufacturing precision deteriorates due to substrate thickness tolerance limitations
Solution Approach 1:
The waveguide is divided into multiple discrete components that can be manufactured with high precision using semiconductor fabrication techniques. Each component is then assembled into a complete waveguide structure, allowing the overall length to be precisely controlled by the arrangement and dimensions of individual segments rather than being limited by single substrate thickness tolerance.
2Adaptability or versatility
If multiple substrates of suitable thickness are combined to realise devices of different length, then waveguide length variability is improved, but manufacturing precision deteriorates due to accumulation of thickness tolerances
Solution Approach 1:
Multiple waveguide components are nested within each other in a telescopic arrangement, where each component can be precisely positioned relative to the others. This nesting structure allows for variable overall length while maintaining high precision through controlled alignment features and interlocking geometries, avoiding the accumulation of tolerances that would occur with simple stacking of multiple substrates.
3Adaptability or versatility
If multiple waveguides are combined to achieve desired overall length, then waveguide length adaptability is improved, but device complexity increases due to alignment requirements
Solution Approach 1:
The waveguide components incorporate asymmetric geometric features such as tapered sections, offset apertures, or non-uniform wall thicknesses that provide self-aligning characteristics during assembly. These asymmetric features create natural alignment references that guide the components into correct relative positions, reducing the complexity of alignment procedures compared to symmetric designs that would require precise external alignment fixtures.
Data Source
AI summary
The present invention relates to a variable length vertically stacked nested waveguide device, comprising a series of, N, waveguide components. Each waveguide component comprises a waveguide layer comprising a waveguide opening, a recess layer comprising a recess, a conductive material coating. The waveguide components are nested within each other to create a nested structure with a combined waveguide opening length defined by the total length of the wave-guide openings in each waveguide components.