Stacked Waveguide RF Module for Compact High-Power Signal Handling
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Solution Overview
Problem
Existing radio frequency modules suffer from large parasitic power losses and are not suitable for miniaturization due to conductor and dielectric effects, limiting their application in compact systems like CubeSats.
Innovation Solution
A compact radio frequency module design using a stack of parallel metal plates with integrated waveguides and flexible circuit boards, allowing for high-performance signal transmission and processing in a compact form factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional waveguide modules with coaxial interconnections are used, then high power signals and wide bandwidths are achieved, but size and mass are large
Solution Approach 1:
The waveguide system is segmented into modular components: metal plates with integrated waveguide channels, support circuit boards, and flexible circuit boards. This segmentation allows each component to be optimized independently and assembled into a compact configuration that maintains high power handling while reducing overall mass compared to conventional monolithic waveguide modules.
Solution Approach 2:
The patent implements nesting by placing support circuit boards and flexible circuit boards within and between the metal plates. The flexible circuit boards are nested within the circuit block structure, allowing interconnections to be integrated into the existing volume rather than adding external bulk, thus reducing overall mass while maintaining power signal integrity.
2Power
If conventional waveguide modules are used, then high power signals are achieved, but volume is large
Solution Approach 1:
The patent transitions from conventional planar waveguide layouts to a three-dimensional stacked architecture. Multiple metal plates are stacked with waveguide channels extending through them, and support circuit boards are positioned at different heights. This vertical dimensionality allows compact integration of multiple functions within a reduced volume while maintaining high power signal pathways.
Solution Approach 2:
Support circuit boards and flexible circuit boards are nested within the metal plate structure. The flexible circuit boards are inserted through openings in the metal plates and routed within the circuit block, utilizing the internal volume efficiently. This nesting eliminates the need for separate external mounting space, significantly reducing overall module volume while preserving power handling capabilities.
3Volume of stationary object
If planar transmission lines are used, then compact design is achieved, but parasitic power losses are large
Solution Approach 1:
The patent applies different structural qualities to different parts of the transmission path. Critical high-power signal pathways are implemented as enclosed waveguide channels within the metal plates, which have low parasitic losses. Less critical control and lower frequency signals use flexible circuit boards and support circuit boards. This local differentiation ensures that where parasitic losses matter most (high power paths), the structure provides protection, while other areas use simpler compact connections.
4Power
If conventional waveguide modules are used, then high power signals are achieved, but miniaturization is limited
Solution Approach 1:
The waveguide system is divided into discrete metal plate modules, each containing specific waveguide channels and functions. This segmentation enables independent optimization of each module's size and allows selective assembly based on power requirements. Smaller power applications can use fewer or smaller plates, achieving miniaturization while maintaining adequate power handling for the application.
Solution Approach 2:
The patent exploits the vertical dimension by stacking metal plates and positioning support circuit boards at different heights. This three-dimensional arrangement allows the system to achieve the required power handling volume efficiency, reducing the footprint and overall size compared to conventional planar waveguide modules while maintaining high power signal pathways.
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
Enables very compact and miniaturized RF modules with high sensitivity and power handling capabilities, suitable for applications in CubeSats and other space-constrained environments.
Implementation Method 1
a plurality of radio frequency waveguides defined by channels in the metal plates so as to carry radio frequency signals within the circuit block
Implementation Method 2
conductor 'skin' and dielectric effects
Data Source
AI summary
A radio frequency module is disclosed comprising: a radio frequency circuit block which comprises a stack of at least two metal plates and a plurality of radio frequency waveguides defined by channels in the metal plates so as to carry radio frequency signals within the circuit block; and one or more radio frequency processing components arranged within the circuit block to interact with the signals carried by the waveguides.