High Density Waveguide Assembly for 5G Testing
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Solution Overview
Problem
Conventional Automatic Test Equipment (ATE) systems experience signal loss and reduced patch antenna pitch due to large waveguide flanges and elongated signal paths, which limit high-frequency testing efficiency and space utilization.
Innovation Solution
A high-density waveguide assembly composed of machined metal plates forming channels, with a transition adapter for thermal isolation and an air barrier to prevent heat transfer, allowing for tighter pitch and efficient signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional waveguide flanges are used to mate waveguide and tester electronics, then signal transmission is achieved, but the large flange dimensions increase signal path length and reduce patch antenna pitch density
Solution Approach 1:
The waveguide flange is segmented into multiple smaller aperture elements arranged in a grid pattern, allowing the signal path to be divided into multiple parallel channels. This segmentation enables tighter pitch between antenna elements while maintaining adequate signal path length for high-frequency operation.
Solution Approach 2:
The invention transitions from a single large circular flange to a two-dimensional array of smaller rectangular apertures. This dimensional change allows multiple signal paths to coexist in the same physical footprint, increasing pitch density without proportionally increasing the overall flange area.
2Area of stationary object
If conventional large waveguide flanges are used, then mechanical stability is maintained, but space utilization is reduced and adjacent waveguides cannot be closely mounted
Solution Approach 1:
The large circular flange is segmented into multiple smaller rectangular aperture elements distributed across the surface. This segmentation reduces the area required for each individual signal path while maintaining overall structural stability through the distributed arrangement of multiple stable mounting points.
Solution Approach 2:
Multiple smaller waveguide apertures are merged into a single integrated flange structure, allowing adjacent waveguides to be closely mounted while sharing common mechanical support. This merging enables efficient space utilization without sacrificing the mechanical stability that would be required for each individual waveguide.
3Reliability
If elongated signal paths are used in conventional ATE systems, then signal transmission is achieved, but signal loss increases at high frequencies
Solution Approach 1:
The signal path is segmented into multiple parallel channels through the array of rectangular apertures, allowing signals to travel shorter distances in each channel. This segmentation reduces cumulative signal loss at high frequencies while maintaining reliable signal transmission through redundant parallel paths.
Data Source
AI summary
Embodiments of the present disclosure use a customizable ganged waveguide that comprises a top metal plate and a bottom metal plate with trenches that come together in a way so as to form waveguide channels. The waveguide assembly of the present invention also comprises a waveguide adapter affixed to a first end of the ganged waveguide and operable to conduct the signal to a tester. Further, it comprises an air barrier affixed to a second end of the ganged waveguide to prevent air from flowing from the ganged waveguide to a printed circuit board connected at the second end. Finally, it comprises a tuning plate comprising double ridge slots configured to allow maximal signal to be transferred to the printed circuit board from the ganged waveguide.