Waveguide Interface Assembly with Foldable Split Ring
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Solution Overview
Problem
Existing waveguide interfaces face challenges with incorrect assembly due to identical split ring halves, complex installation, high material costs, and increased weight, resulting from multiple components and precision machining, which hinder manufacturing cost efficiencies and ease of installation.
Innovation Solution
A single contiguous split ring with a web portion that can be easily folded and retained without additional tools, combined with an overbody featuring alignment protrusions and a waveguide seal, reduces the number of components and eliminates the need for precision metal machining, utilizing interference fits and snap features for alignment and retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional split ring waveguide interfaces are used with multiple components and precision machining, then manufacturing precision and reliability are improved, but manufacturing cost and device complexity increase significantly
Solution Approach 1:
The patent combines multiple discrete components (split rings, overhousing, gaskets, fasteners) into a single integrated waveguide interface assembly. The split ring halves are formed as one piece, and the overhousing is molded as a single component, eliminating the need for assembly of multiple parts and reducing complexity while maintaining precision through molded features.
Solution Approach 2:
The waveguide interface assembly performs multiple functions in a single component: the split ring provides both mechanical retention and sealing surfaces, the overhousing provides structural support and alignment features, and integrated gaskets provide sealing. This multi-functionality reduces the number of components needed while maintaining manufacturing precision.
2Ease of manufacture
If traditional split ring waveguide interfaces are used with identical halves, then manufacturing simplicity is improved, but assembly reliability deteriorates due to delivery errors
Solution Approach 1:
The patent introduces asymmetry by providing alignment protrusions on one split ring half and corresponding alignment grooves on the other half. This asymmetric feature set ensures that the split rings can only be assembled in the correct orientation, preventing delivery errors while maintaining manufacturing simplicity through injection molding or die casting.
3Reliability
If additional retaining bands or o-ring gaskets are added to prevent assembly errors, then assembly reliability is improved, but device complexity and weight increase
Solution Approach 1:
The patent merges the retaining function and sealing function into the integrated waveguide interface assembly. The split ring itself provides retention through interference fit with the overhousing, and integrated gaskets provide sealing, eliminating the need for separate retaining bands or additional o-ring gaskets.
Solution Approach 2:
The waveguide interface assembly is designed to be self-retaining and self-sealing. The interference fit between the split ring and overhousing, along with integrated gaskets, provides automatic retention and sealing without requiring additional components or complex assembly operations.
4Manufacturing precision
If precision metal machining is used to form overhousing and split rings, then manufacturing precision is improved, but material cost and weight increase
Solution Approach 1:
The patent replaces precision metal machining with injection molding or die casting processes. These molding processes can achieve the required precision surfaces through tooling, eliminating the need for subsequent machining operations and reducing material waste. The molded components can also be designed with optimized wall thicknesses to reduce weight.
Solution Approach 2:
The patent changes the manufacturing parameters from precision metal machining to injection molding or die casting. This parameter change allows for the use of lighter materials, reduces material costs through more efficient material utilization, and achieves precision surfaces through the molding process itself rather than post-processing.
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
This design simplifies assembly, reduces material costs, and minimizes weight by using injection molding or die casting, while ensuring precise alignment and sealing, thereby enhancing manufacturing efficiency and reducing the complexity of waveguide interfaces.
Implementation Method 1
a first half and a second half joined by a web portion. The web portion allows the first and second halves to be folded towards one another
Implementation Method 2
at least one alignment protrusion formed in a waveguide side of the split ring to mate with a corresponding alignment hole formed in the interface end shoulder, thereby rotationally aligning and retaining the split ring within the overbody
Implementation Method 3
an outer snap protrusion located along the split ring periphery that mates with a corresponding snap groove formed in the overbody shoulder
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A waveguide interface for a waveguide having a split ring (10) with a first half (12) and a second half (14) joined by a web portion (16). The split ring first half (12) and second half (14) having an inner surface (18) configured to mate with an exterior of the waveguide (20), the first half and the second half foldable towards each other and around the exterior of the waveguide, along the web portion (16). An overbody (30) with a bore (32) is dimensioned to receive the waveguide therethrough; the bore having a shoulder (36) at an interface end (34) dimensioned to receive the split ring (10).