Millimeter Waveguide Interface Precision Mating Surface Alignment
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Solution Overview
Problem
Current waveguide interfaces for millimeter and sub-millimeter wave applications face challenges in achieving precise alignment, leading to degraded electrical performance due to misalignment issues, especially at frequencies above 110 GHz, where conventional alignment pin and hole techniques are inadequate.
Innovation Solution
A waveguide interface design that acts as both a mating surface and a precision alignment mechanism, utilizing a centrally located precision mating surface and diametrically opposed rotational alignment pins and holes with a looser fitment, eliminating the need for multiple precision alignment pins and holes, and relying on the concentricity of the mating interfaces for accurate alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional alignment pin and hole techniques are used, then waveguide interfaces can be assembled, but misalignment occurs leading to degraded electrical performance at high frequencies
Solution Approach 1:
The patent merges the alignment function and mating surface function into a single integrated interface structure. The precision mating surface at the center of the flange serves both as the electrical contact point and the alignment reference, eliminating the need for separate alignment pins and holes that caused misalignment issues at high frequencies.
Solution Approach 2:
The patent extracts and removes the conventional alignment pin and hole features from the waveguide interface design. By eliminating these separate alignment components, the design avoids the misalignment problems that occurred when pins and holes did not perfectly coincide, thereby improving electrical performance at millimeter and sub-millimeter wave frequencies.
2Manufacturing precision
If multiple precision alignment pins and holes are used, then alignment accuracy improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines multiple alignment functions into a single centralized precision mating surface feature. Instead of requiring multiple pins and holes distributed around the flange, the design uses one central precision feature that provides both alignment and electrical mating, significantly reducing structural complexity.
Solution Approach 2:
The central precision mating surface performs multiple functions simultaneously: it serves as the alignment reference, the electrical contact point, and the mechanical mating feature. This multi-functionality eliminates the need for separate alignment pins and holes, reducing both complexity and manufacturing difficulty.
3Speed
If waveguide size is reduced for higher frequencies, then frequency range increases, but relative misalignment impact increases
Solution Approach 1:
The patent applies local quality by concentrating precision requirements at the central mating surface rather than distributing them across multiple features. The single precision feature location allows for optimized local manufacturing processes that can achieve the required tolerances more easily than multiple distributed features would require.
Solution Approach 2:
By merging all alignment functions into the central mating surface, the patent reduces the number of tolerance accumulation points. With only one critical feature location instead of multiple pins and holes, the system maintains better alignment precision even as waveguide dimensions shrink for higher frequency operations.
Data Source
AI summary
A waveguide interface for millimeter wave and sub-millimeter wave applications adapted to couple and uncouple abutting waveguide sections wherein said waveguide interface acts as both a mating surface and a precision alignment mechanism. The waveguide interface comprises a first member having a first waveguide defined therein, a second member having a second waveguide similar in cross-section to said first waveguide defined therein, a means for mating said first member and said second member comprising a centrally located precision mating surface through which propagates electromagnetic energy and additionally comprising at least one pair of diametrically opposed rotational alignment pins and holes located a specified distance from said centrally located precision-mating surface, and wherein said pins and holes are in mating relation of looser fitment than said centrally located precision mating surface.