EP3206067A1 - Waveguides - Google Patents
Waveguides Download PDFInfo
- Publication number
- EP3206067A1 EP3206067A1 EP16275023.6A EP16275023A EP3206067A1 EP 3206067 A1 EP3206067 A1 EP 3206067A1 EP 16275023 A EP16275023 A EP 16275023A EP 3206067 A1 EP3206067 A1 EP 3206067A1
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- EP
- European Patent Office
- Prior art keywords
- waveguide
- connecting end
- cavity
- sleeve member
- sections
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Ceased
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01P—WAVEGUIDES; RESONATORS, LINES, OR OTHER DEVICES OF THE WAVEGUIDE TYPE
- H01P1/00—Auxiliary devices
- H01P1/04—Fixed joints
- H01P1/042—Hollow waveguide joints
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01P—WAVEGUIDES; RESONATORS, LINES, OR OTHER DEVICES OF THE WAVEGUIDE TYPE
- H01P5/00—Coupling devices of the waveguide type
- H01P5/02—Coupling devices of the waveguide type with invariable factor of coupling
- H01P5/022—Transitions between lines of the same kind and shape, but with different dimensions
- H01P5/024—Transitions between lines of the same kind and shape, but with different dimensions between hollow waveguides
Definitions
- This invention relates generally to a waveguide, and a method of manufacturing a waveguide, for use in, for example, communication or radar applications.
- Waveguides are generally used for connecting together transmitting and receiving equipment in, for example, communication or radar systems.
- a waveguide typically comprises a transmission line formed from a hollow conducting tube providing a conduit through which electromagnetic waves are propagated, and may be of any cross-sectional shape, such as, square, rectangular, circular or elliptical, as well as containing single or pairs of opposing ridges.
- waveguides are commonly provided with some means of connecting adjacent waveguide sections.
- RF Radio Frequency
- waveguide sections are each provided with flanged ends and connections to components and other discrete waveguide sections are made by using threaded bolts to pull together the flanged ends of the waveguides to form a contacting joint.
- Flange designs tend to be standardised and, in combination with the above-mentioned fixing bolts, provide the required alignment between waveguides with sufficient mechanical integrity to resist the applied physical forces occurring in service: in a space application, for example, such loads may arise in vibration during launch and differential thermal expansion when in orbit.
- PIM Passive intermodulation
- a waveguide comprising first and second waveguide sections, each waveguide section comprising a main body portion and a connecting end, said first and second waveguide sections being longitudinally aligned to define a conduit therethrough with a butted interface therebetween, the waveguide further comprising a sleeve member over said butted interface, wherein at least one cavity is defined between an inner surface of said sleeve member and an outer surface of a connecting end at least one of said first and second waveguide sections, said at least one cavity having a chemical adhesive therein operative to join said first and second waveguide sections together.
- a connecting end of at least one of said first and second waveguide sections may have a pair of circumferential, spaced apart ridges on its outer surface, said ridges defining a groove, wherein said cavity may be defined between an inner wall of said sleeve member and said groove.
- the circumferential ridges may define an external diameter of said respective connecting end that substantially matches the inner diameter of said sleeve member.
- a maximum distance between said ridges and an inner wall of said sleeve member may be 0.025mm or less.
- the connecting ends of said first and second waveguide sections may be substantially identical, said butted interface may be substantially flat and substantially perpendicular to a waveguide axis defined by said conduit, and said sleeve member may comprise a tubular member configured to surround said butted interface.
- the connecting end of each of said first and second waveguide sections may have a pair of circumferential, spaced apart ridges on its outer surface, said ridges defining a groove, wherein respective cavities may be defined between an inner wall of said sleeve member and said groove and each said cavity has a chemical adhesive therein.
- the or each connecting edge may have a third circumferential ridge on its outer surface located adjacent its distal end.
- the connecting end of said first waveguide section may comprise a male end piece and the connecting end of said second waveguide section may comprise a female end portion including a sleeve portion for receiving said male end portion and aligning said waveguide sections with a choked interface therebetween.
- the use of a choke design herein may desensitise the electrical performance of the waveguide to the contact conditions and improve PIM performance.
- the male end piece may include a recess extending from its distal end of length one quarter of the waveguide wavelength, and the recess, together with a gap between said male and female end pieces of length one quarter of said waveguide wavelength, may thus define said choked interface.
- a method of manufacturing a waveguide comprising the steps of providing first and second waveguide sections, each waveguide section comprising a main body portion and a connecting end, longitudinally aligning said first and second waveguide sections being to define a conduit therethrough with a butted interface therebetween, providing a sleeve member over said butted interface, wherein at least one cavity is defined between an inner surface of said sleeve member and an outer surface of a connecting end at least one of said first and second waveguide sections, and providing a chemical adhesive in said at least one cavity to join said first and second waveguide sections together.
- the sleeve member may have at least one hole therein, and the method may include the step of injecting said chemical adhesive into said cavity through said at least one hole.
- the method may include the step of applying a preload to said butted interface prior to introducing said chemical adhesive into said at least one cavity.
- the method may include the steps of determining, in respect of a bond-line provided by said chemical adhesive within said cavity, a maximum strength under shear load, identifying a thickness of said bond-line associated with said determined maximum strength, and providing a first and/or second waveguide section having a connecting end with a cavity having a height substantially matching said thickness.
- a waveguide section for use in a method substantially as described above, comprising a main body portion and a connecting end, wherein a pair of circumferential, spaced apart ridges is provided on an outer surface of said connecting end, said ridges defining a groove.
- a connecting end for a waveguide section substantially as described above, comprising a generally tubular member having a pair of circumferential ridges provided on its outer surface, in spaced apart relation and defining a groove therebetween, said connecting end being configured to be affixed to an end of a waveguide section.
- a connecting end for a second waveguide section for use in a method substantially as described above with a first waveguide section substantially as described above, wherein said connecting end comprises a sleeve member configured to receive the connecting end of said first waveguide section, said connecting member being configured to be affixed to an end of said second waveguide section.
- a waveguide section 10 comprises a transmission line formed from a hollow conducting tube of generally rectangular cross-section, providing a conduit through which electromagnetic waves can be propagated, in use.
- the transmission line comprises two sections: a main body 12 and a connecting end 14.
- the outer profile of the main body 12 is generally uniform and may be of any known configuration.
- the connecting end 14 is of the same general cross-sectional shape as the main body 12 and extends concentrically therefrom so as to provide a continuous conduit 13 through the waveguide section, but the overall cross-sectional area of the connecting end 14 is slightly smaller than that of the main body 12 such that there is a small stepped portion 15 where they meet.
- a first dam 16 is located at the distal end of the connecting end 14, i.e. furthest from the main body 12.
- a second dam 18 is located adjacent the stepped portion 15 between the main body 12 and the connecting end 14.
- a third dam 20 is provided close to, but spaced apart from, the first dam 16 to define a circumferential groove 17 therebetween.
- the elongate section of the connecting end 14 between the second and third dams 18, 20 defines a second, wider circumferential groove 19.
- the ends of the section defining the groove 19 are joined or formed integrally with the second and third dams 18, 20 by respective convex (fillet) corners or so-called rounds 21 which have the effect of reducing stress within the waveguide wall.
- a sleeve 22 is employed.
- the sleeve 22 comprises a rigid tube of generally rectangular cross-section (in this case) defining a channel therethrough that has inner dimensions to closely fit the outer dimensions of the connecting ends 14 of the waveguide sections (but insufficient to accommodate the outer dimensions of the main body 12), such that the connecting ends can be inserted, via the open ends of the channel, into the sleeve 22 until further insertion of the respective waveguide section is prevented when the end of the sleeve 22 hits the stepped portion 15 between the connecting end 14 and the main body 12.
- the sleeve 22 is provided with holes 24, 26 in the upper and lower walls. More specifically, in this exemplary embodiment, two pairs of holes 24 are provided in the 'upper' wall of the sleeve 22 (in the orientation illustrated) and located such that, two abutted waveguide section connecting ends 14 are positioned within the sleeve channel, each pair of holes 24 is adjacent a respective wide circumferential groove 19 defined between second and third dams 18, 20 of the respective connecting end 14. Indeed, it can be seen that, with the sleeve in situ over a pair of abutted connecting ends, pockets 19a are defined between the grooves 19 and the adjacent inner wall of the sleeve 22.
- a pair of single holes 26 is provided in the 'lower' wall of the sleeve 22, each hole 26 once again being located such that, when two abutted connecting ends 14 are positioned within the sleeve channel, each hole 26 is adjacent a respective 'pocket' 19a defined between a circumferential groove 19 and the adjacent inner wall of the sleeve 22.
- a connecting end 14 of a first waveguide section is inserted into the sleeve channel from one end until that end is adjacent to (but not contacting) the stepped portion 15 of the first connecting end 14.
- a connecting end 14 of a second waveguide section is inserted into the sleeve channel from the opposite end until that end is adjacent to (but not contacting) the stepped portion 15 of the second connecting end, and the distal ends of the first and second connecting ends are essentially abutted, to create a butted (contact) interface 28.
- the holes 24, 26 allow adhesive to be injected into the pockets 19a formed between the connecting ends and the adjacent inner wall of the sleeve 22 (as discussed above).
- the continuous 'pockets' 19a allow the adhesive to flow completely around the waveguide/sleeve interface, and the pocket dimensions (i.e. length and height) can be selected (or adjusted) to optimise the adhesive bond-line thickness and, therefore, overall strength requirement determined/required by the application, as will be discussed in more detail hereinafter.
- the circumferential grooves 19 defining the pockets 19a can, for example, be formed in the respective connecting ends 14 of the waveguide sections by machining the external surface thereof.
- the grooves may additionally or alternatively be formed in the in the inner wall of the sleeve, and the present invention is, once again, not necessarily intended to be limited in this regard.
- greater bond strength is likely to be achieved, at least in most cases, if the adhesive is in direct contact with the base materials.
- Many high performance waveguides are silver plated to minimise loss and, in this case, it is desirable to ensure that the waveguide surfaces forming the pockets 19a are masked, during manufacture, to prevent such plating.
- the sleeve 22 may be desirable for the outer surfaces thereof to be coated or otherwise treated, depending on the environment in which it is to be used.
- the third dam 20 in this exemplary embodiment is intended to prevent adhesive ingress into the waveguide
- the second dam 18 is intended to prevent excess adhesive from escaping through the end of the sleeve 22 and also to assist in improving the alignment of the sleeve on the waveguide.
- the acceptable clearance over the dams 16, 18, 20 may, at least to a certain extent, be a function of adhesive viscosity, as will be understood by a person skilled in the art (i.e. the higher the viscosity, the greater can be the acceptable clearance).
- adhesives that have a relatively low viscosity during curing may require the use of additional sealing means, such as 'O' rings or the like, to seal the waveguide off from the adhesive.
- a simple sleeve arrangement of the type described above enables a strong bond-line to be created in a space-saving manner (compared with, for example, flange connections), so as to connect waveguide sections together in a manner that satisfies the above-described requirement for good mechanical, electrical and RF performance.
- the surfaces to be adhered should be prepared as specified by the manufacturer of the adhesive being used.
- a preload may be applied at the interface 28, prior to bonding.
- such a preload may be applied by means of a clamp 30, or similar arrangement, configured to be affixed to each of the two waveguide sections being joined, and apply a clamping force that pushes and holds the distal ends together (at the interface 28).
- a clamp 30 may be required to provide additional clamping features 32 on the outer surface of the main body 12 of each waveguide section to enable the clamp 30 to be affixed thereto. These features could, for example, be brazed onto, or machined into, the outer walls of the main body 12, depending on the mechanical load requirements.
- the 'sleeve' can be incorporated into one of the waveguide sections so that a male-female geometry is formed.
- the connecting end 36 is, in this case, a 'male' end piece and is of similar configuration to that of the connecting end 14 described above and illustrated in Figure 1 of the drawings.
- the male end piece comprises a generally rectangular tube having first and third circumferential ridges or 'dams' 38, 42 close to the distal end, the first and third dams 38, 42 being spaced apart to define a relatively narrow groove 39 therebetween.
- a second dam 40 is provided close to the end adjacent the main body 34, such that a wider groove 41 is defined between the second and third dams 40, 42 as before.
- a circumferential flange 44 is located behind the second dam 40, immediately adjacent the main body 34.
- the wall of the connecting end 36 is provided with a concentric channel 46 that extends all the way around the wall and inwardly therethrough from the distal end.
- the width (the dimension parallel to the waveguide axis) of the channel 46 is equal to one quarter of the guide wavelength, and is therefore dependent on the frequency band of the application.
- the inner wall of the connecting end 36 is provided with a stepped recess 48 at its distal end.
- the female end piece 50 comprises an insert portion defining a 'sleeve' 52 comprising an outer wall 54 and a shorter, concentric inner wall 56 with a recess therebetween.
- the inner dimensions of the outer wall 54 are such that they closely match those of the outer profile of the corresponding male end piece such that the male end piece can be inserted into the female end piece to form a butted interface at 58 (see Figure 5 ).
- the inner wall 56 of the female end piece rests within the stepped recess 48 in the inner wall of the male end piece (with a gap 59 therebetween) and there is a discrete gap (depicted generally at 60) at the junction of the internal waveguide wall.
- the length of the gap leading from 60 is also one quarter of the waveguide wavelength.
- the male and female end pieces thus arranged and configured, form a choked-waveguide interface, wherein the discrete gap 60 leads into an RF quarter-wave choke circuit (formed by the gap 59 and the channel 46).
- the choke circuit is designed to minimise reflections from the gap 60 over a required frequency band, as will be familiar to a person skilled in the art, and it will be appreciated that the point of contact is, in this case, at 58.
- the circuit is designed so that, at the interface 58, the current crossing is minimised, which desensitises the performance of the junction to the conditions at the junction (which may be advantageous, at least for some applications, when compared with the simpler sleeve design described above with reference to Figures 1 and 2 of the drawings).
- the outer wall 54 of the sleeve defined by the female end piece is provided with a pair of holes 62 in one wall and a single hole 64 in the opposing wall, wherein the holes 62, 64 are located adjacent the wider groove 41 in the male end piece when it is inserted fully within the sleeve.
- the number and specific configuration of the holes 62, 64 may vary and the present invention is not necessarily intended to be limited in this regard.
- Cavities or 'pockets' 41 a are thus created between the wider grooves 41 in the male end piece and the inner surface of the outer wall of the female end piece sleeve.
- pockets 41 a can be formed by machining a groove in the outer surface of the male end piece (as shown) or on the inner surface of the female end piece sleeve, or both, and the present invention is not necessarily intended to be limited in this regard.
- the holes 62, 64 in the outer wall of the female end piece sleeve allow adhesive to be injected into the pockets 41 a.
- the continuous pockets 41 a allow the adhesive to flow completely around the interface between the male and female end pieces and, once again, the pocket dimensions can be designed/adjusted to optimise the adhesive bond-line thickness and overall strength requirement determined by the application. As before, the pockets 41a will typically be shallow and designed to maximise the adhesive bond-line strength depending on the adhesive used, and the length of the bond-line can be adjusted to the requirements of the application.
- the male and female end pieces can be attached to a standard waveguide using the same or similar methods to those used in the art for connecting flanges thereto.
- the end pieces could be torch brazed onto the waveguide in a manner that will be known to a person skilled in the art.
- a preload may be applied to the assembly in order to ensure good contact pressure at the interface 58 and thereby minimise surface effects (i.e. oxide layers) upon insertion loss and PIM.
- a preload may be applied by means of a temporary clamp 70 or any other suitable means, as will be apparent to a person skilled in the art.
- an epoxy paste adhesive i.e. relatively high viscosity
- Hysol ® 9395 may be used which is a two-component adhesive system which is non-metallic and cures at ambient temperatures, but has excellent strength properties at temperatures of 350°F/177°C and higher.
- a BR127 primer can be used to prepare the surfaces to be adhered.
- the adhesive used will be dependent on many factors, including the specific configuration of the end pieces, the material of which the waveguide is made and the application in which the resultant waveguide is to be used.
- an adhesive that cures to a hard resin consistency may be required to ensure that it can maintain the preload applied prior to bonding and maintain good electrical performance.
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Abstract
A waveguide comprising first and second waveguide sections, each waveguide section comprising a main body portion (12) and a connecting end (14), said first and second waveguide sections being longitudinally aligned to define a conduit therethrough with a butted interface (28) therebetween, the waveguide further comprising a sleeve member (22) over said butted interface (28), wherein at least one cavity (19a) is defined between an inner surface of said sleeve member (22) and an outer surface of a connecting end (14) of at least one of said first and second waveguide sections, said at least one cavity (19a) having a chemical adhesive therein operative to join said first and second waveguide sections together.
Description
- This invention relates generally to a waveguide, and a method of manufacturing a waveguide, for use in, for example, communication or radar applications.
- Waveguides are generally used for connecting together transmitting and receiving equipment in, for example, communication or radar systems. A waveguide typically comprises a transmission line formed from a hollow conducting tube providing a conduit through which electromagnetic waves are propagated, and may be of any cross-sectional shape, such as, square, rectangular, circular or elliptical, as well as containing single or pairs of opposing ridges.
- Regardless of the application in which waveguides are to be used, they are commonly provided with some means of connecting adjacent waveguide sections. The successful connection of waveguides for good Radio Frequency (RF) performance requires that the signals being carried by the waveguides are not significantly reflected, absorbed or distorted by the junction, i.e. the junction offers no appreciable discontinuity to the flow of microwave power. This requires that the internal cross-sections on each side of the junction are well aligned, there is low electrical resistance across the interface and that the point of good contact (i.e. low electrical resistance) occurs at the inside wall of the waveguide, where the electrical currents are generated by the passing signals within.
- To this end, various mechanical joints are available, but traditionally, waveguide sections are each provided with flanged ends and connections to components and other discrete waveguide sections are made by using threaded bolts to pull together the flanged ends of the waveguides to form a contacting joint. Flange designs tend to be standardised and, in combination with the above-mentioned fixing bolts, provide the required alignment between waveguides with sufficient mechanical integrity to resist the applied physical forces occurring in service: in a space application, for example, such loads may arise in vibration during launch and differential thermal expansion when in orbit.
- In communication systems, where a single waveguide may be carrying high level signals to be transmitted using two or more carrier frequencies, as well as low level received signals, another issue can occur, known as passive intermodulation. Passive intermodulation (PIM) is the generation of interfering signals caused by nonlinearities in the mechanical components of a system, and occurs when two signals mix together (amplitude modulation) to produce sum and difference signals and products within the same band, causing distortion. These effects can occur at waveguide interfaces and a common approach to minimising the effect is to ensure that there is a high contact pressure at the inside wall, usually achieved by providing a raised contact lip around the inside wall so the contact force applied by the fixing bolts is concentrated at this point.
- In view of the proven electrical performance of bolted flanges, and similar mechanical joints, together with the reversibility and resultant flexibility thereof, they have long provided the most widely accepted method of joining waveguide sections to each other and/or other interfaces.
- However, in modern communication satellites, for example, there can be hundreds or even thousands of waveguide junctions and the resultant mass of flanges and associated fixings can cause significant issues. For instance, the flanges require additional space to be provided at each joint as well as sufficient access to enable the fixing bolts to be tightened. Furthermore, more complex antennas may have many waveguides feeding into them, and in some cases there may be insufficient room for traditional flanged connections.
- It is an object of aspects of the present invention to address at least some of these issues and, in accordance with a first aspect of the present invention, there is provided a waveguide comprising first and second waveguide sections, each waveguide section comprising a main body portion and a connecting end, said first and second waveguide sections being longitudinally aligned to define a conduit therethrough with a butted interface therebetween, the waveguide further comprising a sleeve member over said butted interface, wherein at least one cavity is defined between an inner surface of said sleeve member and an outer surface of a connecting end at least one of said first and second waveguide sections, said at least one cavity having a chemical adhesive therein operative to join said first and second waveguide sections together.
- In an exemplary embodiment, a connecting end of at least one of said first and second waveguide sections may have a pair of circumferential, spaced apart ridges on its outer surface, said ridges defining a groove, wherein said cavity may be defined between an inner wall of said sleeve member and said groove.
- The circumferential ridges may define an external diameter of said respective connecting end that substantially matches the inner diameter of said sleeve member. A maximum distance between said ridges and an inner wall of said sleeve member may be 0.025mm or less.
- The connecting ends of said first and second waveguide sections may be substantially identical, said butted interface may be substantially flat and substantially perpendicular to a waveguide axis defined by said conduit, and said sleeve member may comprise a tubular member configured to surround said butted interface. In this case, the connecting end of each of said first and second waveguide sections may have a pair of circumferential, spaced apart ridges on its outer surface, said ridges defining a groove, wherein respective cavities may be defined between an inner wall of said sleeve member and said groove and each said cavity has a chemical adhesive therein.
- The or each connecting edge may have a third circumferential ridge on its outer surface located adjacent its distal end.
- The connecting end of said first waveguide section may comprise a male end piece and the connecting end of said second waveguide section may comprise a female end portion including a sleeve portion for receiving said male end portion and aligning said waveguide sections with a choked interface therebetween. The use of a choke design herein may desensitise the electrical performance of the waveguide to the contact conditions and improve PIM performance.
- The male end piece may include a recess extending from its distal end of length one quarter of the waveguide wavelength, and the recess, together with a gap between said male and female end pieces of length one quarter of said waveguide wavelength, may thus define said choked interface.
- In accordance with another aspect of the present invention, there is provided a method of manufacturing a waveguide comprising the steps of providing first and second waveguide sections, each waveguide section comprising a main body portion and a connecting end, longitudinally aligning said first and second waveguide sections being to define a conduit therethrough with a butted interface therebetween, providing a sleeve member over said butted interface, wherein at least one cavity is defined between an inner surface of said sleeve member and an outer surface of a connecting end at least one of said first and second waveguide sections, and providing a chemical adhesive in said at least one cavity to join said first and second waveguide sections together.
- In an exemplary embodiment, the sleeve member may have at least one hole therein, and the method may include the step of injecting said chemical adhesive into said cavity through said at least one hole.
- The method may include the step of applying a preload to said butted interface prior to introducing said chemical adhesive into said at least one cavity.
- The method may include the steps of determining, in respect of a bond-line provided by said chemical adhesive within said cavity, a maximum strength under shear load, identifying a thickness of said bond-line associated with said determined maximum strength, and providing a first and/or second waveguide section having a connecting end with a cavity having a height substantially matching said thickness.
- In accordance with another aspect of the present invention there is provided a waveguide section for use in a method substantially as described above, comprising a main body portion and a connecting end, wherein a pair of circumferential, spaced apart ridges is provided on an outer surface of said connecting end, said ridges defining a groove.
- In accordance with yet another aspect of the present invention, there is provided a connecting end for a waveguide section substantially as described above, comprising a generally tubular member having a pair of circumferential ridges provided on its outer surface, in spaced apart relation and defining a groove therebetween, said connecting end being configured to be affixed to an end of a waveguide section.
- In accordance with a further aspect of the invention, there is provided a connecting end for a second waveguide section for use in a method substantially as described above with a first waveguide section substantially as described above, wherein said connecting end comprises a sleeve member configured to receive the connecting end of said first waveguide section, said connecting member being configured to be affixed to an end of said second waveguide section.
- These and other aspects of the invention will be apparent from the following specific description, in which embodiments of the present invention are described, by way of examples only, and with reference to the accompanying drawings, in which:
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Figure 1 is a schematic perspective view of a waveguide section according to a first exemplary embodiment of the present invention; -
Figure 2 is a schematic cut-away perspective view of a waveguide according to an exemplary embodiment of the present invention; -
Figure 3 is a schematic perspective view of a waveguide according to an exemplary embodiment of the present invention illustrating the application of a preload during the manufacturing process; -
Figure 4 is a schematic perspective view of a waveguide section according to another exemplary embodiment of the present invention, illustrating a male end piece; -
Figure 5 is a schematic cut-away perspective view of a waveguide according to an exemplary embodiment of the present invention; -
Figure 6 is a schematic perspective view of a waveguide section according to an exemplary embodiment of the present invention, illustrating a female end piece; and -
Figure 7 is a schematic perspective view of a waveguide according to an exemplary embodiment of the present invention illustrating the application of a preload during the manufacturing process. - Referring to
Figure 1 of the drawings, a waveguide section 10 according to an exemplary embodiment of the present invention comprises a transmission line formed from a hollow conducting tube of generally rectangular cross-section, providing a conduit through which electromagnetic waves can be propagated, in use. The transmission line comprises two sections: amain body 12 and a connectingend 14. The outer profile of themain body 12 is generally uniform and may be of any known configuration. The connectingend 14 is of the same general cross-sectional shape as themain body 12 and extends concentrically therefrom so as to provide acontinuous conduit 13 through the waveguide section, but the overall cross-sectional area of the connectingend 14 is slightly smaller than that of themain body 12 such that there is a smallstepped portion 15 where they meet. - Three concentric circumferential ridges (or 'dams') 16, 18, 20 are provided on the outer wall of the connecting
end 14. Afirst dam 16 is located at the distal end of the connectingend 14, i.e. furthest from themain body 12. Asecond dam 18 is located adjacent thestepped portion 15 between themain body 12 and the connectingend 14. Athird dam 20 is provided close to, but spaced apart from, thefirst dam 16 to define acircumferential groove 17 therebetween. The elongate section of the connectingend 14 between the second and 18, 20 defines a second, widerthird dams circumferential groove 19. The ends of the section defining thegroove 19 are joined or formed integrally with the second and 18, 20 by respective convex (fillet) corners or so-calledthird dams rounds 21 which have the effect of reducing stress within the waveguide wall. - In a method, according to an exemplary embodiment of the invention, of manufacturing a waveguide by joining two such waveguide sections together, and referring additionally to
Figure 2 of the drawings, asleeve 22 is employed. Thesleeve 22 comprises a rigid tube of generally rectangular cross-section (in this case) defining a channel therethrough that has inner dimensions to closely fit the outer dimensions of the connectingends 14 of the waveguide sections (but insufficient to accommodate the outer dimensions of the main body 12), such that the connecting ends can be inserted, via the open ends of the channel, into thesleeve 22 until further insertion of the respective waveguide section is prevented when the end of thesleeve 22 hits thestepped portion 15 between the connectingend 14 and themain body 12. It can be particularly seen inFigure 2 of the drawings that thesleeve 22 of a length to accommodate, within its channel, two abutted connectingends 14 of respective waveguide sections, with the opposing end edges thereof each adjacent to, but not in contact with, a respectivestepped portion 15. - The
sleeve 22 is provided with 24, 26 in the upper and lower walls. More specifically, in this exemplary embodiment, two pairs ofholes holes 24 are provided in the 'upper' wall of the sleeve 22 (in the orientation illustrated) and located such that, two abutted waveguidesection connecting ends 14 are positioned within the sleeve channel, each pair ofholes 24 is adjacent a respective widecircumferential groove 19 defined between second and 18, 20 of the respective connectingthird dams end 14. Indeed, it can be seen that, with the sleeve in situ over a pair of abutted connecting ends, pockets 19a are defined between thegrooves 19 and the adjacent inner wall of thesleeve 22. In this exemplary embodiment, a pair ofsingle holes 26 is provided in the 'lower' wall of thesleeve 22, eachhole 26 once again being located such that, when two abutted connectingends 14 are positioned within the sleeve channel, eachhole 26 is adjacent a respective 'pocket' 19a defined between acircumferential groove 19 and the adjacent inner wall of thesleeve 22. - Thus, in use, a connecting
end 14 of a first waveguide section is inserted into the sleeve channel from one end until that end is adjacent to (but not contacting) thestepped portion 15 of the first connectingend 14. A connectingend 14 of a second waveguide section is inserted into the sleeve channel from the opposite end until that end is adjacent to (but not contacting) thestepped portion 15 of the second connecting end, and the distal ends of the first and second connecting ends are essentially abutted, to create a butted (contact)interface 28. - The
24, 26 allow adhesive to be injected into the pockets 19a formed between the connecting ends and the adjacent inner wall of the sleeve 22 (as discussed above). The continuous 'pockets' 19a allow the adhesive to flow completely around the waveguide/sleeve interface, and the pocket dimensions (i.e. length and height) can be selected (or adjusted) to optimise the adhesive bond-line thickness and, therefore, overall strength requirement determined/required by the application, as will be discussed in more detail hereinafter. It will be appreciated that theholes circumferential grooves 19 defining the pockets 19a can, for example, be formed in the respective connectingends 14 of the waveguide sections by machining the external surface thereof. However, other methods of forming such grooves will be apparent to a person skilled in the art and the present invention is not necessarily intended to limited in this regard. In an alternative exemplary embodiment, the grooves may additionally or alternatively be formed in the in the inner wall of the sleeve, and the present invention is, once again, not necessarily intended to be limited in this regard. Furthermore, it will be understood that greater bond strength is likely to be achieved, at least in most cases, if the adhesive is in direct contact with the base materials. Many high performance waveguides are silver plated to minimise loss and, in this case, it is desirable to ensure that the waveguide surfaces forming the pockets 19a are masked, during manufacture, to prevent such plating. There is not thought to be any requirement for thesleeve 22 to be plated, but it may be desirable for the outer surfaces thereof to be coated or otherwise treated, depending on the environment in which it is to be used. - It is essential for good electrical and RF performance of the resultant waveguide that adhesive is prevented from penetrating into the waveguide or significantly across the butted
interface 28 between first and second connecting ends. This may be achieved by a) ensuring that the butted waveguide faces are accurately machined to be flat and perpendicular to the waveguide axis; b) ensuring that the clearance between the inner wall of thesleeve 22 and the outer faces of the 16, 18, 20 is small, typically, say, 0.025mm or less; and/or c) applying a preload across the butteddams interface 28. - With particular reference to b) above, the
third dam 20 in this exemplary embodiment is intended to prevent adhesive ingress into the waveguide, and thesecond dam 18 is intended to prevent excess adhesive from escaping through the end of thesleeve 22 and also to assist in improving the alignment of the sleeve on the waveguide. However, it will be appreciated that the number and precise location on the connectingend 14 of such dams may vary from that depicted and described above, and the present invention is not necessarily intended to be limited in this regard. The acceptable clearance over the 16, 18, 20 may, at least to a certain extent, be a function of adhesive viscosity, as will be understood by a person skilled in the art (i.e. the higher the viscosity, the greater can be the acceptable clearance). However, adhesives that have a relatively low viscosity during curing may require the use of additional sealing means, such as 'O' rings or the like, to seal the waveguide off from the adhesive.dams - It will be appreciated from the above that a simple sleeve arrangement of the type described above enables a strong bond-line to be created in a space-saving manner (compared with, for example, flange connections), so as to connect waveguide sections together in a manner that satisfies the above-described requirement for good mechanical, electrical and RF performance. It will be appreciated that, in order to achieve the required high quality adhesive joints, the surfaces to be adhered should be prepared as specified by the manufacturer of the adhesive being used. Furthermore, and with reference to c) above, for a simple butted junction, it is important to ensure good contact pressure at the
interface 28. Thus, a preload may be applied at theinterface 28, prior to bonding. Referring toFigure 3 of the drawings, such a preload may be applied by means of aclamp 30, or similar arrangement, configured to be affixed to each of the two waveguide sections being joined, and apply a clamping force that pushes and holds the distal ends together (at the interface 28). In this case, it may be required to provide additional clamping features 32 on the outer surface of themain body 12 of each waveguide section to enable theclamp 30 to be affixed thereto. These features could, for example, be brazed onto, or machined into, the outer walls of themain body 12, depending on the mechanical load requirements. Once the adhesive has been applied and cured, theclamp 30 can be removed. - In alternative exemplary embodiments, the 'sleeve' can be incorporated into one of the waveguide sections so that a male-female geometry is formed. Thus, referring first to
Figure 4 of the drawings, a waveguide section having amain body 34 and amale connecting end 36 is illustrated. The connectingend 36 is, in this case, a 'male' end piece and is of similar configuration to that of the connectingend 14 described above and illustrated inFigure 1 of the drawings. Thus, the male end piece comprises a generally rectangular tube having first and third circumferential ridges or 'dams' 38, 42 close to the distal end, the first and 38, 42 being spaced apart to define a relativelythird dams narrow groove 39 therebetween. Asecond dam 40 is provided close to the end adjacent themain body 34, such that awider groove 41 is defined between the second and 40, 42 as before. Athird dams circumferential flange 44 is located behind thesecond dam 40, immediately adjacent themain body 34. - Referring additionally to
Figure 5 of the drawings, the wall of the connectingend 36 is provided with aconcentric channel 46 that extends all the way around the wall and inwardly therethrough from the distal end. The width (the dimension parallel to the waveguide axis) of thechannel 46 is equal to one quarter of the guide wavelength, and is therefore dependent on the frequency band of the application. The inner wall of the connectingend 36 is provided with a stepped recess 48 at its distal end. - Referring now to
Figure 6 of the drawings, as well asFigure 5 , thefemale end piece 50 comprises an insert portion defining a 'sleeve' 52 comprising anouter wall 54 and a shorter, concentricinner wall 56 with a recess therebetween. The inner dimensions of theouter wall 54 are such that they closely match those of the outer profile of the corresponding male end piece such that the male end piece can be inserted into the female end piece to form a butted interface at 58 (seeFigure 5 ). In this configuration, theinner wall 56 of the female end piece rests within the stepped recess 48 in the inner wall of the male end piece (with agap 59 therebetween) and there is a discrete gap (depicted generally at 60) at the junction of the internal waveguide wall. It will be appreciated that the length of the gap leading from 60 (or recess 48) is also one quarter of the waveguide wavelength. The male and female end pieces, thus arranged and configured, form a choked-waveguide interface, wherein thediscrete gap 60 leads into an RF quarter-wave choke circuit (formed by thegap 59 and the channel 46). The choke circuit is designed to minimise reflections from thegap 60 over a required frequency band, as will be familiar to a person skilled in the art, and it will be appreciated that the point of contact is, in this case, at 58. Thus, the circuit is designed so that, at theinterface 58, the current crossing is minimised, which desensitises the performance of the junction to the conditions at the junction (which may be advantageous, at least for some applications, when compared with the simpler sleeve design described above with reference toFigures 1 and 2 of the drawings). - As shown in
Figures 5 and 6 of the drawings, theouter wall 54 of the sleeve defined by the female end piece is provided with a pair ofholes 62 in one wall and asingle hole 64 in the opposing wall, wherein the 62, 64 are located adjacent theholes wider groove 41 in the male end piece when it is inserted fully within the sleeve. As before, the number and specific configuration of the 62, 64 may vary and the present invention is not necessarily intended to be limited in this regard.holes - Cavities or 'pockets' 41 a are thus created between the
wider grooves 41 in the male end piece and the inner surface of the outer wall of the female end piece sleeve. As before, such pockets 41 a can be formed by machining a groove in the outer surface of the male end piece (as shown) or on the inner surface of the female end piece sleeve, or both, and the present invention is not necessarily intended to be limited in this regard. The 62, 64 in the outer wall of the female end piece sleeve allow adhesive to be injected into the pockets 41 a. The continuous pockets 41 a allow the adhesive to flow completely around the interface between the male and female end pieces and, once again, the pocket dimensions can be designed/adjusted to optimise the adhesive bond-line thickness and overall strength requirement determined by the application. As before, the pockets 41a will typically be shallow and designed to maximise the adhesive bond-line strength depending on the adhesive used, and the length of the bond-line can be adjusted to the requirements of the application.holes - It is anticipated that the male and female end pieces can be attached to a standard waveguide using the same or similar methods to those used in the art for connecting flanges thereto. Thus, for example, in the case of a typical aluminium waveguide, the end pieces could be torch brazed onto the waveguide in a manner that will be known to a person skilled in the art.
- Once again, and as illustrated schematically in
Figure 7 of the drawings, once the male end pieces has been fully inserted into the female end piece, and the surfaces prepared according to the adhesive manufacturer's instructions/specification, a preload may be applied to the assembly in order to ensure good contact pressure at theinterface 58 and thereby minimise surface effects (i.e. oxide layers) upon insertion loss and PIM. Such a preload may be applied by means of atemporary clamp 70 or any other suitable means, as will be apparent to a person skilled in the art. - It will be appreciated that many different types of adhesive may be considered suitable for use in embodiments of the present invention. In some exemplary embodiments, an epoxy paste adhesive (i.e. relatively high viscosity) may be employed. For example, Hysol ® 9395 may be used which is a two-component adhesive system which is non-metallic and cures at ambient temperatures, but has excellent strength properties at temperatures of 350°F/177°C and higher. In this case, a BR127 primer can be used to prepare the surfaces to be adhered. However, the adhesive used will be dependent on many factors, including the specific configuration of the end pieces, the material of which the waveguide is made and the application in which the resultant waveguide is to be used. For example, in some exemplary embodiments, such as those using the simple sleeve configuration described above in relation to
Figures 1 and 2 of the drawings, an adhesive that cures to a hard resin consistency may be required to ensure that it can maintain the preload applied prior to bonding and maintain good electrical performance. - In all cases, manufacturers of commercially available adhesives usually provide data indicative of the specific bond-line thickness required to give maximum strength under shear load. Thus, the height of the pocket (19a, 41 a) can be set to achieve this figure.
- It will be appreciated by a person skilled in the art, from the foregoing description, that modifications and variations can be made to the described embodiments without departing from the scope of the invention as defined by the appended claims.
Claims (16)
- A waveguide comprising first and second waveguide sections, each waveguide section comprising a main body portion and a connecting end, said first and second waveguide sections being longitudinally aligned to define a conduit therethrough with a butted interface therebetween, the waveguide further comprising a sleeve member over said butted interface, wherein at least one cavity is defined between an inner surface of said sleeve member and an outer surface of a connecting end of at least one of said first and second waveguide sections, said at least one cavity having a chemical adhesive therein operative to join said first and second waveguide sections together.
- A waveguide according to claim 1, wherein a connecting end of at least one of said first and second waveguide sections has a pair of circumferential, spaced apart ridges on its outer surface, said ridges defining a groove, wherein said cavity is defined between an inner wall of said sleeve member and said groove.
- A waveguide according to claim 2, wherein said circumferential ridges define an external diameter of said respective connecting end that substantially matches the inner diameter of said sleeve member.
- A waveguide according to claim 3, wherein a maximum distance between said ridges and an inner wall of said sleeve member is 0.025mm or less.
- A waveguide according to any of the preceding claims, wherein the connecting ends of said first and second waveguide sections are substantially identical, said butted interface is substantially flat and substantially perpendicular to a waveguide axis defined by said conduit, and said sleeve member comprises a tubular member configured to surround said butted interface.
- A waveguide according to claim 5, wherein the connecting end of each of said first and second waveguide sections has a pair of circumferential, spaced apart ridges on its outer surface, said ridges defining a groove, wherein respective cavities are defined between an inner wall of said sleeve member and said groove and each said cavity has a chemical adhesive therein.
- A waveguide according to claim 2 or claim 6, wherein the or each connecting edge has a third circumferential ridge on its outer surface located adjacent its distal end.
- A waveguide according to any of claims 1 to 4 or claim 7 when dependent on claim 2, wherein the connecting end of said first waveguide section comprises a male end piece and the connecting end of said second waveguide section comprises a female end portion including a sleeve portion for receiving said male end portion and aligning said waveguide sections with a choked interface therebetween.
- A waveguide according to claim 8, wherein said male end piece includes a recess extending from its distal end of length one quarter of the waveguide wavelength, and wherein said recess, together with a gap between said male and female end pieces of length one quarter of said waveguide wavelength, defines said choked interface.
- A method of manufacturing a waveguide comprising the steps of providing first and second waveguide sections, each waveguide section comprising a main body portion and a connecting end, longitudinally aligning said first and second waveguide sections being to define a conduit therethrough with a butted interface therebetween, providing a sleeve member over said butted interface, wherein at least one cavity is defined between an inner surface of said sleeve member and an outer surface of a connecting end at least one of said first and second waveguide sections, and providing a chemical adhesive in said at least one cavity to join said first and second waveguide sections together.
- A method according to claim 10, wherein said sleeve member has at least one hole therein, and the method includes the step of injecting said chemical adhesive into said cavity through said at least one hole.
- A method according to claim 10 or claim 11, including the step of applying a preload to said butted interface prior to introducing said chemical adhesive into said at least one cavity.
- A method according to any of claims 10 to 12, including the steps of determining, in respect of a bond-line provided by said chemical adhesive within said cavity, a maximum strength under shear load, identifying a thickness of said bond-line associated with said determined maximum strength, and providing a first and/or second waveguide section having a connecting end with a cavity having a height substantially matching said thickness.
- A waveguide section for use in a method according to any of claims 10 to 13, comprising a main body portion and a connecting end, wherein a pair of circumferential, spaced apart ridges is provided on an outer surface of said connecting end, said ridges defining a groove.
- A connecting end for a waveguide section according to claim 14, comprising a generally tubular member having a pair of circumferential ridges provided on aits outer surface, in spaced apart relation and defining a groove therebetween, said connecting end being configured to be affixed to an end of a waveguide section.
- A connecting end for a second waveguide section for use in a method according to any of claims 10 to 13 with a first waveguide section according to claim 14, wherein said connecting end comprises a sleeve member configured to receive the connecting end of said first waveguide section, said connecting member being configured to be affixed to an end of said second waveguide section.
Priority Applications (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP16275023.6A EP3206067A1 (en) | 2016-02-10 | 2016-02-10 | Waveguides |
| US16/075,233 US10673109B2 (en) | 2016-02-10 | 2017-02-08 | Apparatus for connecting first and second waveguide sections comprising an adhesive disposed in cavities between circumferential ridges and a sleeve member |
| ES17704533T ES2871781T3 (en) | 2016-02-10 | 2017-02-08 | Wave guides |
| PCT/GB2017/050308 WO2017137737A1 (en) | 2016-02-10 | 2017-02-08 | Waveguides |
| EP17704533.3A EP3414607B1 (en) | 2016-02-10 | 2017-02-08 | Waveguides |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP16275023.6A EP3206067A1 (en) | 2016-02-10 | 2016-02-10 | Waveguides |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| EP3206067A1 true EP3206067A1 (en) | 2017-08-16 |
Family
ID=55345769
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP16275023.6A Ceased EP3206067A1 (en) | 2016-02-10 | 2016-02-10 | Waveguides |
Country Status (1)
| Country | Link |
|---|---|
| EP (1) | EP3206067A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112397853A (en) * | 2020-10-28 | 2021-02-23 | 中国电子科技集团公司第二十九研究所 | Waveguide flange capable of realizing quick assembling, disassembling and sealing and connecting device thereof |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB964530A (en) * | 1961-09-21 | 1964-07-22 | Standard Telephones Cables Ltd | Improvements in or relating to waveguide reinforcement |
| GB971481A (en) * | 1963-02-21 | 1964-09-30 | Standard Telephones Cables Ltd | Waveguide joint |
| US3374450A (en) * | 1965-11-17 | 1968-03-19 | Litton Prec Products Inc | Waveguide flange and coupling assembly |
-
2016
- 2016-02-10 EP EP16275023.6A patent/EP3206067A1/en not_active Ceased
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB964530A (en) * | 1961-09-21 | 1964-07-22 | Standard Telephones Cables Ltd | Improvements in or relating to waveguide reinforcement |
| GB971481A (en) * | 1963-02-21 | 1964-09-30 | Standard Telephones Cables Ltd | Waveguide joint |
| US3374450A (en) * | 1965-11-17 | 1968-03-19 | Litton Prec Products Inc | Waveguide flange and coupling assembly |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112397853A (en) * | 2020-10-28 | 2021-02-23 | 中国电子科技集团公司第二十九研究所 | Waveguide flange capable of realizing quick assembling, disassembling and sealing and connecting device thereof |
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