Waveguide Connection Using Ridges and Sleeve for Adhesive Containment
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Solution Overview
Problem
Traditional waveguide connection methods, such as flanged connections, face challenges in modern communication satellites due to mass and space constraints, and can cause passive intermodulation and RF performance issues, especially when using multiple waveguide junctions.
Innovation Solution
A waveguide connection method using circumferential ridges and a sleeve member to create recesses for adhesive, preventing adhesive ingress and excess adhesive overflow, which reduces the need for additional sleeve members and highly viscous adhesives, while maintaining RF performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional flanged connections are used to join waveguide sections, then mechanical integrity and alignment are achieved, but mass and space requirements increase significantly
Solution Approach 1:
The patent combines the alignment function and the joining function into a single integrated ridge structure. The circumferential ridges on the waveguide outer surface serve both to align adjacent waveguide sections and to provide the bonding interface for adhesive application, eliminating the need for separate flanges and multiple fastening components.
Solution Approach 2:
The invention extracts the essential functions of traditional flanged connections (alignment and mechanical joining) and implements them through a simplified ridge structure with adhesive bonding. This removes the heavy flange and bolt assembly while retaining the core functional requirements.
2Strength
If traditional flanged connections with multiple bolts are used, then mechanical integrity is achieved, but the number of components and assembly complexity increase
Solution Approach 1:
The patent merges multiple discrete components (flanges, multiple bolts, washers) into a single integrated ridge structure that performs both alignment and joining functions. The adhesive bonding system replaces the multi-component mechanical fastening system.
Solution Approach 2:
The ridge structure is segmented into circumferential ridges at different positions, which allows the adhesive to be applied in a controlled manner through recesses formed between the ridges, simplifying the bonding process while maintaining structural integrity.
3Strength
If adhesive is used to join waveguide sections without recesses, then bonding is achieved, but adhesive ingress into the waveguide and excess adhesive overflow occur
Solution Approach 1:
The outer surface is segmented into circumferential ridges that create distinct recesses between them. These recesses serve as controlled containment zones for the adhesive, allowing it to be applied in specific locations without overflowing into the waveguide interior or spreading uncontrollably on the outer surface.
Solution Approach 2:
The ridge structure creates localized recesses at specific circumferential positions where adhesive is applied. This localizes the bonding action to specific zones, preventing adhesive from spreading to areas where it would cause harm (ingress into the waveguide or overflow on the exterior).
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 method provides a space-saving, high-strength bond-line that minimizes passive intermodulation and maintains excellent RF performance by containing excess adhesive and ensuring accurate alignment, thus addressing the limitations of traditional flanged connections.
Implementation Method 1
a chemical adhesive in each first cavity operative to join the first and second waveguide sections together by means of the sleeve member
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A waveguide comprising first and second waveguide sections, each waveguide section comprising a main body portion (12) and a connecting portion (14) at its distal end, said first and second waveguide sections being longitudinally aligned to define a conduit therethrough with a butted interface (28) therebetween, the connecting portion of each waveguide section having: (i) a first circumferential ridge (16) on its outer surface located adjacent its distal end, (ii) a second circumferential ridge (18) on its outer surface spaced apart from the first circumferential ridge, and (iii) a third circumferential ridge (20) on its outer surface located between said first and second circumferential ridges, such that a first respective recess (19) is defined between said second and third circumferential ridges and a second respective recess (17) is defined between said first and third circumferential ridges; the waveguide further comprising a sleeve member (22) over said butted interface (28), such that a respective first cavity (19a) is defined between an inner surface of said sleeve member (22) and each said first recess (19) and a respective second cavity is defined between the inner surface of said sleeve member (22) and each said second recess (17), each said first cavity (19a) having a chemical adhesive therein operative to join said first and second waveguide sections together by means of said sleeve member (22).