The present invention relates to a combline waveguide filter and a method of making said filter.
Radio frequency (RF) signals can propagate either in free space or in waveguide devices.
An example of such a conventional waveguide is described in patent application WO2017208153, the content of which is incorporated by reference. It consists of a hollow device, the shape and proportions of which determine the propagation characteristics for a given wavelength of the electromagnetic signal. The internal channel section of this device is rectangular. Other channel cross-sections are suggested in this document, including circular shapes.
The waveguide 1 of this prior art comprises a core produced by additive manufacturing by superimposing layers on one another. This core delimits an internal channel intended for guiding waves, the cross-section of which is determined according to the frequency of the electromagnetic signal to be transmitted. The inner surface of the core is covered with a conductive metal layer. The external surface can also be covered with a conductive metal layer which contributes to the rigidity of the device.
Waveguide devices are used to channel RF signals or to manipulate them in the spatial or frequency domain, for example to form a waveguide filter. In particular, the present invention relates to passive waveguide filters that allow filtering of radio frequency signals without the use of active electronics.
Conventional waveguide filters used for radio frequency signals typically have internal apertures of rectangular or circular cross section. The primary purpose of these filters is to suppress unwanted frequencies and pass desired frequencies with minimal attenuation. Attenuations greater than 100 dB or even 120B may be required for filters intended for reception and/or transmission systems in the space domain for example.
Space or aeronautical applications in particular require compact and light waveguide filters. Consequently, important research efforts have been carried out in order to propose waveguide filter geometries that can satisfy these different objectives.
Evanescent mode filters, or combline filters, are for example known. They are essentially composed of several small cavities (below the cutoff frequency) that transmit electromagnetic energy between an input port and an output port. The successive cavities are connected by irises whose dimensions help determine the bandwidth of the filter. Several peaks or posts allow the propagation of the fundamental mode. This type of filters is used for example for the input and output stages of satellite payloads, because of their high selectivity and their reduced mass and size.
Conventional combline waveguide filters are made by machining and assembling different metal subassemblies. These operations are complex and costly. In addition, the weight of the filters thus produced is significant.
An aim of the present invention is to provide a new type of combline waveguide filter that is simpler to manufacture and whose weight is reduced.
According to one aspect, these goals are achieved by means of a combline waveguide filter made of metal by a process including an additive manufacturing step.
The filter may be manufactured by a process including an additive manufacturing step, for example of the SLM type in which a laser or electron beam melts or sinters several thin layers of a powder material.
The additive manufacturing can be seen on the filter thus produced by analyzing the structure of the metal grains thus sintered in layers.
Additive metal manufacturing allows complex shapes to be made by limiting or eliminating assembly steps, thereby reducing manufacturing costs.
Additive manufacturing also allows for the manufacture of combline waveguide filters without or with a reduced number of assembly means between subcomponents, which also reduces the weight of the filter.
Waveguide devices are known to be manufactured by additive printing. However, the complex shapes of combline waveguide filters do not lend themselves to additive manufacturing due to the many cantilevered surfaces, especially the surfaces forming the roof of the resonator cavities.
Most additive printing processes, including selective laser melting (SLM) processes, require a minimum angle, such as 20° or 40°, to avoid the risk of sagging of a newly deposited cantilevered layer. This makes it impossible to print certain portions of the waveguide filter, or at least to print them with the desired precision.
In order to avoid these disadvantages, it is proposed in another aspect that a combline waveguide filter with an unconventional geometry be realized in additive printing, which facilitates high precision additive printing.
To this end, according to one aspect, the combline waveguide filter is provided with at least two resonators, preferably at least four resonators, comprising a cavity provided with a longitudinal axis x, a transverse axis y and a vertical axis z, each cavity being delimited in particular by two walls each extending in a plane perpendicular to the longitudinal axis,
The term “combline waveguide filter” implies that the individual resonators are interconnected by irises. This does not necessarily imply that the resonators are aligned on a single longitudinal or transverse line.
The choice of a non-rectangular cross-section provides additional freedom to make cavities that can be made by metal additive printing with a printing direction p parallel to the longitudinal axis x of the filter, as in
In this way, it is possible to realize metallic waveguide filters in which the layers resulting from additive printing are not parallel to the roof surfaces of the cavities and can be printed without overhang.
This avoids the accuracy problems caused by additive printing on a substrate with an oblique printing surface.
In addition, the density of filters that can be printed simultaneously on a given surface is increased, or the height and number of printing layers is reduced, in both cases improving the speed of additive printing and thus reducing the cost.
Each cavity may include a post extending parallel to the vertical axis within the cavity.
The use of posts in the cavity allows the impedance of the cavity to be modified, thus controlling the resonant frequency of the circuit formed by the cavity and the iris.
In one embodiment, each cavity has a base perpendicular to the vertical axis and substantially planar, and a roof above said base, said roof lacking a planar surface parallel to said base. Thus, it is possible to manufacture the resonators by starting with the base supported by a horizontal printing surface, and then printing the cavity walls and roof which do not have cantilevered horizontal surfaces.
A said post may extend from said base.
The roof may comprise exactly two panels formed by oblique faces connecting said walls and inclined with respect to said base.
The roof can have several flat panels, for example two panels, connected to each other and/or to the base by curved surfaces.
The roof may comprise exclusively curved surfaces connecting said walls together. This variant allows for a vaulted roof that is easier to print in additive printing.
The cross-section of the resonator may vary in the longitudinal direction.
The area of the cross-section may be increasing from each longitudinal end of the cavity toward the longitudinal center of the cavity. Thus, the maximum height of the resonator roof may be at the longitudinal center of the resonator, and the minimum height at one or both longitudinal ends. This increasing and then decreasing slope of the roof in the longitudinal direction facilitates its printing, as the longitudinal edge of the roof forms a self-supporting vault during printing.
At least two longitudinally adjacent cavities may be connected to each other by an iris.
This iris can cross the vertical walls of two adjacent resonators. An iris between two adjacent resonators in the longitudinal direction is referred to as a longitudinal iris.
The cross section of the longitudinal iris may be triangular.
The cross-section of the longitudinal iris may be polygonal, such as forming a quadrilateral, such as a rhombus, rectangle or square.
Multiple irises, such as two irises, may be provided between two longitudinally adjacent resonators. The cross-section of these irises may form a slot. The slot may extend vertically.
At least two transversely adjacent cavities may be connected to each other by an iris.
This iris can cross the roof of two adjacent resonators. An iris between two adjacent resonators in the transverse direction is called a transverse iris.
The transverse irises can form a polyhedron
The transverse iris may form a polyhedron with 4 triangular faces, with two of the faces in the planes of the two adjacent roofs being hollow in order to pass the radio frequency signal between the resonators.
The transverse iris can form a polyhedron with two pentagonal faces, two triangular faces and two trapezoidal faces, the pentagonal faces in the planes of the two roofs being hollow in order to allow the radio frequency signal to pass between the resonators.
The transverse irises may have a rectangular cross-section with the upper edge formed by the intersection of two panels of two interlocking cavities.
The transverse irises may occupy a curved volume, for example if they are supported on flat con roofs.
A single combline waveguide filter may have multiple longitudinal irises of different shapes, and/or multiple transverse irises of different shapes or sections.
At least one cavity of a resonator may be provided with a tuning screw to create an obstruction in the cavity and adjust the resonance frequency. The tuning screw may extend vertically above the post and inserted more or less deeply into the cavity.
At least one iris may have a tuning screw to adjust the passband of the filter. The screw may extend vertically through the top wall of the iris, and into the iris.
At least one cavity may include a hole for chemical cleaning of the interior of the cavity after additive printing. This hole may be removed or modified after cleaning.
The comb waveguide filter may include at least two resonators, for example four or eight or more resonators, interconnected by irises.
The resonators and the irises can be realized in a monolithic way.
The combline waveguide filter may include an input port for an radiofrequency electromagnetic signal into the filter and an output port for the radiofrequency electromagnetic signal out of the filter.
The ports may be formed in machined flanges and assembled, for example by bonding, to the additively printed portion of the filter.
The ports may be provided with a connector for a coaxial cable.
According to one aspect, the invention also relates to a method of manufacturing a combline waveguide filter, comprising additively manufacturing said resonators by superimposing layers extending in planes perpendicular to the vertical axis.
The method may include machining a flange with an input port and a flange with an output port, and bonding said flanges to said cavities.
Example embodiments of the invention are shown in the description illustrated by the appended figures in which:
The illustrated resonator 3 is provided with an input port 51 for an input radio frequency signal and an output port for the filtered signal, although in practice this resonator is intended to be connected to other resonators via an iris or irises 4, as will be discussed later.
The resonator 3 comprises a cavity 30 delimited by a base 34, a roof with two panels 35-36, and two vertical walls 31 and 32. The roof panel 35 is connected to the base by a curved surface 350, and to the other panel 36 by a second curved surface 361 forming the roof edge. The panel 36 is connected to the base 34 by a third curved surface 360. As in other embodiments, the curved surfaces 350, 360, 361 are curved in the x-y transverse plane. In this example, the curved surfaces 350, 360, 361 are not curved in the other planes.
The longitudinal axis x is parallel to the roof edge, and perpendicular to the vertical walls 31-32. The transverse axis y is perpendicular to the longitudinal axis x. The base 34 extends in the x-y plane, called the horizontal plane. The z-axis, called the vertical axis, is perpendicular to the x-y plane. It should be noted that the vertical axis corresponds to the printing direction p during additive printing; this direction is therefore vertical during printing, but not necessary during the use of the filter, which can be implemented in any orientation.
The resonator preferably includes a post 33 that extends into the cavity 30 perpendicularly from the base, without reaching the roof 35-36. The height of the post defines the impedance of the resonator and thus the cutoff frequency of the filter for the fundamental mode.
The cross-section of the cavity 30, in the y-z plane, is non-rectangular, and substantially triangular in this example. The resonator is printed with the base 34 perpendicular to the printing direction, on the printing table. This geometry avoids cantilevered surfaces during printing.
Other examples of resonators and filters including such resonators are illustrated in the other figures and described below. For the sake of brevity, the features of these other resonators already presented and described in connection with
The threaded hole allows a tuning screw 38 to be inserted from the edge of the roof 35-36 and vertically to the post 33; by adjusting the depth of insertion of this screw into the cavity, the cutoff frequency is adjusted. By inserting the screw deeper, the cut-off frequency fc of the filter is reduced.
Such a tuning screw can be provided with all the resonators written below.
The input port 51 allows a radio frequency signal to be introduced into the cavity 30, for example from a waveguide or coaxial cable. The height h along the z-axis of the center of the input port determines both the quality of the coupling and the quality factor Qe; the higher h, the better the coupling, but at the expense of the quality factor of the resonator.
The dimensions of the iris determine the properties of the filter. Increasing the height of the iris improves the coupling between cavities, but also increases the bandwidth of the filter.
The filters described above include two adjacent resonators. However, a comb waveguide filter may comprise more than two resonators, for example at least four resonators, for example eight or more resonators. These resonators may be juxtaposed in the longitudinal x direction and/or in the transverse y direction in order to make the best use of the available volume and to achieve a compact combline filter.
Other types of transverse irises may be provided between resonators in the same row. Other longitudinal irises may be provided between different rows.
It is also possible to provide multiple irises between two adjacent rows of a filter 1.
It is possible to provide longitudinal irises of different cross-sections within the same filter.
It is possible to provide cross-irises of different sections within the same filter
The height of the resonators can be between 8 and 15 mm. Their width along the transverse axis x can be between 15 and 30 mm. Their length may be between 10 and 18 mm. The diameter of the chemical cleaning holes 37 is advantageously less than 2 mm. The frequency adjustment screws 38 may have a diameter between 2 and 5 mm, for example between 3 and 4 mm. The bandwidth adjustment screws 39 may have a diameter between 1.5 and 2.5 mm, for example 2 mm. The cut-off frequency can be between 8 and 30 GHz, with a bandwidth between 100 and 300 MHz.
The above description shows different resonators with one or more input ports, different resonators with one or more irises of different types, and different resonators without input ports and irises. These different aspects can be combined with each other. For example, a resonator of any shape, such as one of the shapes described above, may be associated with an iris or set of irises of any of the types described above, and/or with an input port or output port. Resonators of different shapes and sizes may be combined in the same waveguide.
A typical combline guide done filter comprises a resonator with an input port and at least one iris, a resonator with an output port and at least one iris, and a plurality of resonators connected, for example, in series or in series-parallel circuits between the resonator with the input port and the resonator with the output port, the resonators being connected together by longitudinal and/or transverse irises.
Number | Date | Country | Kind |
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FR2012634 | Dec 2020 | FR | national |
Filing Document | Filing Date | Country | Kind |
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PCT/IB2021/061314 | 12/3/2021 | WO |