Patent Application
20240304974
The present invention relates to a waveguide device and more particularly to a flexible waveguide device capable of adapting its length and the orientation of its ends according to the circumstances in order to facilitate its assembly. The flexible waveguide device according to the invention has the further advantage of absorbing vibrations or shocks. The invention also relates to a method of manufacturing such a device.
Radio frequency (RF) signals can propagate either in free space or in waveguide devices. These waveguide devices are used to channel RF signals or to manipulate them in the spatial or frequency domain.
The present invention relates in particular to passive RF devices that allow the propagation and manipulation of radio frequency signals without the use of active electronics. Passive waveguides can be divided into three distinct categories:
The present invention relates in particular to the first category above, hereinafter collectively referred to as waveguides. Examples of such devices include waveguides per se, filters, antennas, mode converters, etc. Examples of such devices include waveguides per se, filters, antennas, mode converters, etc. They can be used for signal routing, frequency filtering, separation or recombination of signals, transmission or reception of signals into or from free space, etc.
Waveguides are typically made of conductive material, for example of metal, by extrusion or bending. The realization of waveguides with complex cross-sections by conventional manufacturing methods is difficult and costly. However, recent work has shown that waveguide components can be produced using additive manufacturing methods, for example by 3D printing. It is known, in particular, that waveguides formed in conductive materials can be additively manufactured.
Flexible waveguides made by additive manufacturing are also known.
As an example, WO18029455 discloses a waveguide assembly for an RF signal network, comprising a plurality of waveguides, wherein at least two of the plurality of waveguides are integrally formed with each other. At least one of the plurality of waveguides may be flexible, which may improve interface loads and allow adjustment of interface planes to facilitate mounting.
GB1078575 discloses a conventional method of manufacturing “bellows” type flexible waveguides. A mandrel having the same shape as the inside of a flexible waveguide is made. A layer of copper or copper alloy is then electroformed onto the mandrel to achieve the required thickness on the mandrel surface. A flange is then welded to each end of the applied layer. Finally, a protective rubber film is molded onto the surface of the electroformed layer between the two flanges and the mandrel is then removed.
The waveguide described in GB1078575 has in particular the disadvantage of being difficult to conceive, which has a non-negligible impact on the cost of this type of waveguide.
WO2019/243766 discloses an elongated flexible waveguide section for radio frequency signals. The waveguide section is corrugated in the longitudinal direction, and the waveguide section is at least partially corrugated in a circumferential direction perpendicular to the longitudinal direction. The manufacture of such a waveguide is relatively difficult to implement.
An aim of the present invention is to provide a method of manufacturing a flexible waveguide device exempt from the limitations of the prior art.
In particular, an aim of the present invention is to provide a flexible waveguide device that is easy to conceive by an improved manufacturing process.
Another aim of the present invention is to provide a flexible waveguide device at a reduced cost.
According to the invention, these aims are achieved in particular by means of a method of manufacturing a flexible waveguide device, of the “bellows” type, comprising a core through which a channel passes in order to guide a radio frequency signal at a given frequency. The method comprises the following steps:
In an embodiment, the electroformed metal layer has a homogeneous thickness between 0.05 and 5 mm and preferably between 0.1 and 0.5 mm.
In an embodiment, the mandrel is manufactured so as to obtain a hollow mandrel.
In an embodiment, the mandrel is dissolved away with a dissolving solution.
In an embodiment, the mandrel and the metal layer formed on the outer shell of the mandrel are immersed in a solvent bath.
In an embodiment, two fixing flanges are fixed to the respective ends of the core, preferably by brazing.
In an embodiment, two fixing flanges are integrated into the geometry of the mandrel so that the fixing flanges are integral with the respective ends of the core.
In an embodiment, inserts or other fixing elements are assembled on the mandrel and then encapsulated in the metal layer when the latter is electroformed onto the outer shell of the mandrel to form the core of the device.
Another aspect of the invention relates to a flexible waveguide device, of the bellows type, for guiding a radio frequency signal at a given frequency range. The device comprises:
The flexible corrugated portion is formed on a part of the outer side walls of the core and comprises a plurality of circumferential ribs around the core which are adjacent to each other. Each rib lies in a plane orthogonal to the channel axis when the flexible waveguide device is in an unfolded configuration. Each rib is devoid of corrugation along its circumference.
In an embodiment, the flexible corrugated portion may or may not be centered with respect to the two fixing flanges.
In an embodiment, the distance between each adjacent rib may vary between 0.1 and 5.0 mm and preferably between 0.5 and 2.0 mm as the device moves from a compressed configuration to an expanded configuration.
In an embodiment, a plurality of distinct flexible corrugated portions are formed on respective parts of the outer side walls of the core.
In an embodiment, three flexible corrugated portions are formed on the outer sidewall part of the core. Two of the three flexible corrugated portions are respectively adjacent to the first and second fixing flanges while one of the three flexible corrugated portions is centered or not with respect to said fixing flanges.
In an embodiment, the cross-section of the core along the channel is circular, elliptical, oval, hexagonal, square or rectangular.
In an embodiment, the cross-section of the core is non-constant along the channel.
In an embodiment, the two fixing flanges comprise each a reinforcement in order to increase the rigidity of the flanges.
In an embodiment, the outer side walls of the core are an electroformed part. Inserts or other fixing elements are encapsulated in the electroformed part.
Examples of embodiments of the invention are shown in the description illustrated by the attached figures in which.
The flexible waveguide device 10, of the bellows type, illustrated in
Two fixing flanges 18a, 18b are connected to respective ends of the core 12. One or both of the fixing flanges 18a, 18b may include a reinforcement (not shown) so as to increase the rigidity thereof.
A flexible corrugated portion 20, of the bellows type, is formed on the outer side walls 14a of the core 12
The flexible portion 20 of the waveguide device 10 is centered with respect to the two fixing flanges 18a, 18b and comprises a plurality of adjacent ribs 22. These ribs 22 extend along the perimeter of the core 12 in a substantially rectangular trajectory. However, the trajectory of the ribs may vary depending on the geometry of the core 12.
For example, the ribs 22 may follow a circular trajectory. The distance between each adjacent rib may vary between 0.1 and 5.0 mm and preferably between 0.5 and 2.0 mm as the device moves from a compressed configuration to an extended configuration.
The waveguide device 10, illustrated in particular in
In the present application, the term “additive manufacturing” refers to any method of manufacturing the mandrel 30 by adding material, according to computer data stored on the computer medium and defining the geometric shape of the mandrel.
In addition to stereolithography, the term also refers to other manufacturing methods such as liquid or powder curing or coagulation, including but not limited to binder jetting, DED (Direct Energy Deposition), EBFF (Electron Beam Freedom fabrication), FDM (Fused Deposition Modeling) PFF (Plastic Free Forming), aerosol, BPM (Ballistic Particle Manufacturing), SLM (Selective Laser Melting), SLS (Selective Laser Sintering), ALM (Additive Layer Manufacturing), polyjet, EBM (Electron Beam Melting), photopolymerisation, etc.
The mandrel 30 is preferably manufactured so as to obtain a hollowed mandrel with a minimum wall thickness determined so that the mandrel 30 has sufficient mechanical strength for the electrodeposition step while having the advantage of being able to be dissolved rapidly, the minimum time for dissolving the mandrel being of the order of 4 hours.
The mandrel 30 obtained by additive manufacturing is subjected to a surface treatment to make it suitable for the deposition of a metal layer 25 by electrodeposition (
Copper or copper alloys, such as copper-tin, copper-zinc, or silver or silver alloy with a thickness varying between 0.05 mm and 5 mm is deposited on the surface of the mandrel by electrodeposition. Uniformity of thickness over the entire layer of deposited metal is very important to obtain a flexible waveguide with good mechanical properties.
Once the metal layer is deposited on the outer shell of the mandrel 30 by electroforming to form the core 12 of the device 10, the mandrel 30 and the metal layer 25 formed on the outer shell of the mandrel are immersed in a solvent bath.
The dissolving bath may be a succession of acidic or basic baths with immersion times ranging from 1 hour to 48 hours.
In an embodiment, during manufacturing of the flexible waveguide device 10, the two fixing flanges 18a, 18b are fixed to the respective ends of the core 12, for example by brazing. In an alternative embodiment, the two fixing flanges 18a, 18b are integrated into the geometry of the mandrel so that the fixing flanges are integral with the respective ends of the core 12.
Inserts or other (non-illustrated) fixing elements may be assembled onto the mandrel 30 and then encapsulated in the metal layer when the latter is electroformed onto the outer shell of the mandrel 30 to form the core 12 of the device 10.
The waveguide device 10 may comprise a plurality of separate flexible corrugated portions formed on respective parts of the outer side walls of the core.
For example, the waveguide device 10 may comprise three flexible corrugated portions that are formed on the outer sidewall portion 14a of the core 12. Two of the three flexible corrugated portions are respectively adjacent to the first and second fixing flanges 18a, 18b while one of the three flexible corrugated portions is centered or not with respect to the two fixing flanges 18a, 18b.
The cross-section of the core 12 along the channel 16 of the waveguide device may for example be circular, elliptical, oval, hexagonal, square or rectangular.
The waveguide device obtained by this manufacturing method has a high mechanical bending strength and thus facilitates its assembly.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2006344 | Jun 2020 | FR | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2021/055303 | 6/16/2021 | WO |
