Some devices (e.g., radar) use electromagnetic signals to detect and track objects. The electromagnetic signals are transmitted and received using one or more antennas. An antenna may be characterized in terms of gain, beam width, or, more specifically, in terms of the antenna pattern, which is a measure of the antenna gain as a function of direction. Certain applications may benefit from precisely controlling the antenna pattern. A folded waveguide is a millimeter-sized component that may be used to improve desirable antenna characteristics; gradient lobes may be reduced or eliminated as unwanted electromagnetic radiation is allowed to leak from a folded or sinusoidal shaped channel (e.g., filled with air or other dielectric), which is embedded in the small component. Forming a small waveguide with a complex internal channel structure can be too difficult and, therefore, too expensive to be produced at a cost and scale (e.g., millions of units) required to support some industries that require improved antenna characteristics, including automotive and communication technology sectors.
This document describes techniques, systems, apparatuses, and methods for utilizing a two-part folded waveguide with horns. In one example, an apparatus includes a two-part folded waveguide with horns, which may be an air waveguide (in this document referred to as a waveguide). Securing the two parts of the waveguide does not require use of a conductive bonding layer, such as a dielectric paste, during manufacture because of a horn structure on a plurality of radiation slots of the waveguide. The horn structure allows for alternative means to secure the first part of the waveguide to the second part. The described waveguide includes a channel which forms a rectangular opening along a longitudinal axis at one end, and a sinusoidal shape that folds back and forth about the longitudinal axis that extends in the longitudinal direction along the channel. The channel further forms a plurality of radiation slots in the shape of a horn, each of the radiation slots including a respective hole extending through one of multiple surfaces of the two-part folded waveguide that defines the channel. The first part of the waveguide is separated from the second part of the waveguide by a layer of material.
In another example, a method for manufacturing a two-part folded waveguide with horns is described in accordance with techniques, systems, apparatuses, and methods of this disclosure. The method includes forming two parts of a two-part folded waveguide with horns, aligning the two parts of the two-part folded waveguide with horns, and securing the two parts of the two-part folded waveguide with horns. The two parts of the two-part folded waveguide with horns may be stamped, etched, cut, machined, cast, molded, or formed by injection molding. The two parts of the two-part folded waveguide with horns may be secured by a plastic fastener, a metal fastener, or a double-sided adhesive.
This Summary introduces simplified concepts related to a two-part folded waveguide with horns, which are further described below in the Detailed Description and Drawings. In addition, systems, as well as other techniques, systems, apparatuses, and methods are described below. This Summary is not intended to identify essential features of the claimed subject matter, nor is it intended for use in determining the scope of the claimed subject matter.
The details of a two-part folded waveguide with horns are described in this document with reference to the following figures:
The same numbers are often used throughout the drawings and the detailed description to reference like features and components.
Overview
Some devices (e.g., radar) use electromagnetic signals to detect and track objects. The electromagnetic signals are transmitted and received using one or more antennas. An antenna may be characterized in terms of gain, beam width, or, more specifically, in terms of the antenna pattern, which is a measure of the antenna gain as a function of direction. Certain applications may benefit from precisely controlling the antenna pattern. A folded waveguide is a millimeter-sized component that may be used to improve some antenna characteristics; gradient lobes may be reduced or eliminated as unwanted electromagnetic energy is allowed to leak from a folded or sinusoidal shaped channel (e.g., filled with air) embedded in the component. Forming a waveguide with an internal folded channel can be too difficult and, therefore, too expensive to be produced at a cost and scale (e.g., millions of units) required to support some industry, including automotive and communication technology sectors.
In contrast, this document describes a two-part folded waveguide with horns. For example, an apparatus includes a two-part folded waveguide having multiple surfaces that define a channel, the two-part folded waveguide including a first part of the waveguide with a first surface from the multiple surfaces, the first surface having a sinusoidal shape that folds back and forth about a longitudinal axis that extends in a longitudinal direction through the channel and a plurality of radiation slots. Each of the radiation slots is in a shape of a horn that forms a respective hole extending through the first surface and into the channel. At least one second surface from the multiple surfaces is part of the first part and is perpendicular to the first surface to define an upper half of walls of the channel that are normal to the first surface. The first part further includes a first feature at one end of the waveguide defining a portion of a rectangular opening in the longitudinal direction and through to the channel. A second part of the waveguide is arranged adjacent to and parallel with the first part with a third surface from the multiple surfaces being parallel to the first surface and having the same sinusoidal shape as the first surface. At least one fourth surface from the multiple surfaces is between the second surface and the third surface and perpendicular to the first surface and the third surface. The fourth surface defines a lower half of the walls of the channel. The second part further includes a second feature at the same end of the waveguide as the first feature; the second feature defines a remaining portion of the rectangular opening that is not defined by the first feature.
In addition, this document describes an example method for manufacturing a two-part folded waveguide with horns. The method includes forming a first part of the waveguide such that the first part includes a first surface from the multiple surfaces, the first surface having a sinusoidal shape that folds back and forth about a longitudinal axis that extends in a longitudinal direction through the channel and a plurality of radiation slots, each of the radiation slots in a shape of a horn that forms a respective hole extending through the first surface and into the channel. Forming the first part further includes including at least one second surface from the multiple surfaces that is perpendicular to the first surface to define an upper half of walls of the channel that are normal to the first surface. The first part is further formed with a first feature at one end of the waveguide, the first feature defining a portion of a rectangular opening in the longitudinal direction and through to the channel. The method further includes forming a second part of the waveguide such that the second part of the waveguide includes a third surface from the multiple surfaces having the same sinusoidal shape as the first surface. The forming of the second part includes forming at least one fourth surface from the multiple surfaces to be perpendicular to the third surface. The fourth surface defines a lower half of the walls of the channel. The second part further includes a second feature at the same end of the waveguide as the first feature; the second feature defines a remaining portion of the rectangular opening that is not defined by the first feature. The method further includes arranging the second part of the waveguide to be adjacent to and parallel with the first part of the waveguide by orientating the first part of the waveguide with the second part of the waveguide to align the first feature of the first part of the waveguide with the second feature of the second part of the waveguide and aligning the upper half of the walls of the channel that are normal to the first surface of the first part of the waveguide with the lower half of the walls of the channel that are perpendicular to the third surface to cause the sinusoidal shape of the first and second parts of the waveguide to be aligned in parallel. In some examples there is a gap between the first and second parts. In other examples, there is a zero gap (e.g., direct contact between the two parts) or a small gap filled with materials of various types. If a gap is present, any unwanted effects that would otherwise result in an antenna pattern, are compensated by the horns.
This is just one example of the described techniques, systems, apparatuses, and methods of a two-part folded waveguide with horns. This document describes other examples and implementations.
Example Apparatus
The waveguide 102 may have multiple surfaces 110, 112, 114, and 116 that define a channel 104, or hollow core, for capturing the energy of electromagnetic signals transmitted through air. The channel 104 may be filled with air, or another suitable dielectric material. The channel 104 has a folding or a sinusoidal shape 118, which folds back and forth about a longitudinal axis 120 that extends in a longitudinal direction along a length of the waveguide 102, and a corresponding length of the channel 104.
The waveguide 102 may be constructed from metal, plastic, wood, or combinations thereof. No matter the construction material, it may be difficult to form a waveguide with a hollow core that has the sinusoidal shape 118 of the channel 104.
It is desirable to form the waveguide 102 with at least two separate parts (e.g. part one 106 and part two 108). However, this can introduce gaps and other irregularities in size or shape of the waveguide 102, which can cause unwanted effects in an antenna pattern. As is described below, the waveguide 102 can compensate for any unwanted effects that would otherwise come from forming the waveguide 102 out of more than one part, even if there are gaps. This compensation is provided at least in part by using a plurality of radiation slots 122 that are shaped as the horns 124. Each radiation slot from the plurality of radiation slots 122 includes a longitudinal slot that is parallel to the longitudinal axis 120 to produce a horizontal-polarized antenna pattern. The specific size and position of the radiation slots 122 can be determined using modeling and testing to arrive at their position and size to produce the particular desired antenna pattern.
The waveguide 102 includes at least two-parts, a first part 106 and a second part 108. When oriented and arranged in parallel (e.g., with some gap or no gap between), the first part 106 and the second part 108 create the channel 104. That is, the channel 104 includes interior surfaces formed by the surfaces 110, 112, 114, and 116 of the two parts 106 and 108. Specifically, the first part 106 includes the first surface 110, which provides a ceiling to the channel 104, which gives the channel 104 the sinusoidal shape 118 thereof (e.g., for eliminating gradient lobes). The first surface 110 also provides the plurality of radiation slots 122, which each have a shape of a horn 124. Each of the horns 124 is configured to form a respective hole extending through the first surface 110 and into the channel 104, to allow for electromagnetic energy leakage. The horns 124 can allow electromagnetic energy to escape the channel 104, thereby filtering the electromagnetic energy that remains in the channel 104 to be within a specific operating frequency for the channel 104 (or waveguide 102).
The first part 106 of the waveguide 102 also includes at least one second surface 112. The second surface 112 is perpendicular to the first surface 110 and is configured to define an upper half 126 of walls of the channel 104 that are normal to the first surface 110. When aligned, the two parts 106 and 108 divide the waveguide 102 (e.g., in half) laterally, which is perpendicular to the longitudinal axis 120. The first surface 110 provides the ceiling of the channel 104, through which the radiation slots 122 are formed, and the upper half of the walls that follow the sinusoidal shape 128 on both sides of the of the channel 104.
The waveguide 102 includes an opening (e.g., a rectangular opening) at one end of the channel 104 in the longitudinal direction 120, at which electromagnetic energy can enter the channel 104. A first feature 128 of the first part 106 is positioned at the same end of the waveguide 102 as the opening. The first feature 128 defines a portion of the opening that is created by a portion of the first surface 110 combined with a portion of the second surface 112 with the upper half 126 of the walls.
The second part 108 of the waveguide 102 is arranged adjacent to and parallel with the first part 106, in such a way so the channel 104 is formed. The second part 108 of the waveguide includes the third surface 114, and at least one fourth surface, including the fourth surface 116. The third surface 114 may be parallel to the first surface 110 and may include the same sinusoidal shape 118 as the first surface 110. The third surface 114 can be considered to form a floor of the channel 104, that is parallel to and opposite the ceiling formed by the first surface 110.
The fourth surface 116 is arranged between the second surface 112 and the third surface 114. The fourth surface 116 is perpendicular to both the first surface 110 and the third surface 114 so that the fourth surface 116 is congruent with the second surface 112. The fourth surface 116 is configured to define a remaining, lower half 130 of the walls of the channel 104. In other words, the fourth surface 116 is configured to extend or lengthen the walls partially formed by the second surface 112 to adjoin the walls to the floor of the channel 104 defined by the third surface 114. The lower half 130 of the walls meet the upper half 126 of the walls to form a consistent interior surface, on either side of the channel 104, that folds back and forth in the sinusoidal shape 118.
The second part 108 of the waveguide 102 also includes a second feature 132 at the same end of the waveguide as the first feature 128. The second feature 132 defines a remaining portion of the opening to the channel 104, which is not already defined by the first feature 128. In other words, when the first part 106 and the second part 108 are arranged in parallel as shown in
As such, the waveguide 102 with horns 124 provides several advantages over other waveguides, including being be easier to manufacture, in addition to providing a better antenna pattern that is free from gradient lobes or other unwanted antenna pattern characteristics that may appear when multiple parts are used and gaps are formed. By using a specific horn-shaped radiation slot, in combination with a two-part formation of a folded or sinusoidal-shaped internal channel 104, the waveguide 102 demonstrates enhanced stability for manufacturing purposes over a typical waveguide.
The plurality of radiation slots 122 may be evenly distributed along the longitudinal axis 120 through the channel 104. A common distance 210 between each of the plurality of radiation slots 122 along the longitudinal axis 120 is one half a desired operating frequency or signal wavelength (e.g., λ/2), intended to be transmitted or received using the two-part folded waveguide 102 with horns 124. This separation by the common distance 210 can prevent grating lobes and ensure undesired wavelengths of electromagnetic energy are filtered out from a specific desired operating frequency for the channel 104 (or waveguide 102). The common distance 210 is less than one wavelength of the electromagnetic radiation that that is not allowed to leak out of the channel 104 by the radiation slots 122.
An individual horn 228 from the radiation slots 122 in the shape of a horn 124 on the waveguide 102 is illustrated. The radiation slots 122 in the shape of a horn 124 allow the first part 106 of the waveguide 102 to be constructed with additional structural stability resulting from the enhanced thickness 230 of the waveguide 102. The structural stability ensures quality in manufacturing of the millimeter-sized waveguide 102 which may otherwise suffer from gradient lobes resulting from manufacturing defects. The problem of forming a small waveguide 102 at the scale (e.g., millions of units) required to support some industries that require improved antenna characteristics is solved by the enhanced structural stability, which is compensated for using the horns 124 to provide an affordable waveguide solution.
The waveguide 102 can be formed using a combination of one or more of the above techniques, and other techniques as well, for maintaining alignment and even separation between the two parts 106 and 108. The enhanced thickness 230 of the waveguide 102, resulting from the addition of a plurality of radiation slots 122 in the shape of a horn 124 as shown in
Example Method
At operation 502, each part of a two-part waveguide with horns is formed. For example, the two parts of the two-part folded waveguide with horns may be stamped, etched, cut, machined, cast, molded, or formed in some other way as a result of the increased stability provided by the horns. At operation 504, each part of the two parts of the waveguide with horns are aligned. Optimal alignment ensures the waveguide operates without suffering from gradient lobes resulting from manufacturing defects. At operation 506, each part of the two parts of the waveguide with horns are secured. The two parts of the two-part folded waveguide with horns may be secured by an external fastener or internal fastener including a plastic fastener, a metal fastener, or a double-sided adhesive.
In aspects, the method may include manufacturing two parts of a two-part folded waveguide with horns having multiple surfaces that define a channel by at least forming a first part of the waveguide. The first part of the waveguide includes a first surface from one of the multiple surfaces. The first surface is shown having a folding or a sinusoidal shape that folds back and forth about a longitudinal axis that extends along the longitudinal axis of the first part. The waveguide also possesses a plurality of radiation slots, each of the radiation slots is in a shape of a horn. The horn is configured to form a respective hole extending through the first surface and into the channel. The horn can let electromagnetic energy escape the channel as the waveguide filters the electromagnetic energy to be within a specific frequency for the channel.
The first part of the waveguide possess at least one second surface from the multiple surfaces. The second surface is perpendicular to the first surface and is configured to define an upper half of walls of the channel that are normal to the first surface. The first part also includes a first feature at one end of the waveguide that defines a portion of a rectangular opening in the longitudinal direction and through to the channel.
A second part of the waveguide may be arranged adjacent to and parallel with the first part. The second part of the waveguide includes a third surface from the multiple surfaces. The third surface may be parallel to the first surface and may include the same sinusoidal shape as the first surface. The second part of the waveguide includes at least a fourth surface from the multiple surfaces between the second surface and the third surface. The fourth surface being perpendicular to the first surface and the third surface, the fourth surface defining a lower half of the walls of the channel. The second part of the waveguide includes a second feature at the same end of the waveguide as the first feature, the second feature defining a remaining portion of the rectangular opening that is not defined by the first feature.
In additional aspects, the method may include arranging the second part of the waveguide to be adjacent to and parallel with the first part of the waveguide. The first part of the waveguide is oriented with the second part of the waveguide to align the first feature of the first part of the waveguide with the second feature of the second part of the waveguide. The upper half of the walls of the channel that are normal to the first surface of the first part of the waveguide are aligned with the lower half of the walls of the channel that are perpendicular to the third surface to cause the sinusoidal shape of the first and second parts of the waveguide to be aligned in parallel. Arranging the second part of the waveguide to be adjacent to and parallel with the first part of the waveguide may include evenly separating the first part of the waveguide from the second part of the waveguide by a layer of material measuring less than twenty percent of a total size of the channel defined by the lower and upper halves of the walls.
The first part of the waveguide may be secured to the second part of the waveguide with a fastener that maintains the first part and second part of the waveguide in a parallel arrangement. The fastener may be an external fastener or an internal fastener. The fastener may be a plastic fastener or a metal fastener. The first part of the waveguide may be secured to the second part of the waveguide by an adhesive bond between the second surface and the fourth surface. The first part of the waveguide and the second part of the waveguide may be secured through an adhesive bond between the second surface and the fourth surface. The adhesive bond may be a dielectric, an epoxy, a glue, or a double-sided tape.
Example Graph
In the following section, additional examples of a folded waveguide for antenna are provided.
An apparatus comprising a two-part folded waveguide having multiple surfaces that define a channel, the two-part folded waveguide including: a first part of the waveguide comprising: a first surface from the multiple surfaces, the first surface having: a sinusoidal shape that folds back and forth about a longitudinal axis that extends in a longitudinal direction through the channel; and a plurality of radiation slots, each of the radiation slots in a shape of a horn that forms a respective hole extending through the first surface and into the channel; at least one second surface from the multiple surfaces, the second surface being perpendicular to the first surface to define an upper half of walls of the channel that are normal to the first surface; and a first feature at one end of the waveguide, the first feature defining a portion of a rectangular opening in the longitudinal direction and through to the channel; a second part of the waveguide arranged adjacent to and parallel with the first part, the second part of the waveguide comprising: a third surface from the multiple surfaces, the third surface being parallel to the first surface and having the same sinusoidal shape as the first surface; at least one fourth surface from the multiple surfaces between the second surface and the third surface, the fourth surface being perpendicular to the first surface and the third surface, the fourth surface defining a lower half of the walls of the channel; and a second feature at the same end of the waveguide as the first feature, the second feature defining a remaining portion of the rectangular opening that is not defined by the first feature.
The apparatus of any preceding example, wherein the first part of the waveguide is evenly separated from the second part of the waveguide by a layer of material.
The apparatus of any preceding example, wherein the first part of the waveguide is evenly separated from the second part of the waveguide by a layer of material measuring less than twenty percent of a total size of the channel defined by the lower and upper halves of the walls.
The apparatus of any preceding example, wherein the layer of material separating the first part of the waveguide from the second part of the waveguide comprises air.
The apparatus of any preceding example, wherein the layer of material separating the first part of the waveguide from the second part of the waveguide comprises a dielectric material other than air configured to maintain the first part of the waveguide at a fixed position relative to the second part of the waveguide.
The apparatus of any preceding example, wherein the first part of the waveguide is secured to the second part of the waveguide with a metal fastener configured to maintain the first part of the waveguide at a fixed position relative the second part of the waveguide.
The apparatus of any preceding example, wherein the first part of the waveguide is secured to the second part of the waveguide with a plastic fastener configured to maintain the first part of the waveguide at a fixed position relative to the second part of the waveguide.
The apparatus of any preceding example, wherein the first part of the waveguide is secured to the second part of the waveguide with a double-sided adhesive configured to maintain the first part of the waveguide at a fixed position relative to the second part of the waveguide.
The apparatus of any preceding example, wherein the two-part folded waveguide comprises one or more materials including plastic, metal, composite materials, or wood.
The apparatus of any preceding example, wherein the plurality of radiation slots comprises different horn shapes, including: a triangular shaped pyramid horn; a square shaped pyramid horn; a pentagonal shaped pyramid horn; a hexagonal shaped pyramid horn; a circular shaped pyramid horn; or a rectangular shaped pyramid horn.
The apparatus of any preceding example, wherein the plurality of radiation slots are evenly distributed between the rectangular opening and an end of the waveguide arranged opposite the rectangular opening along the longitudinal axis that extends in the longitudinal direction through the channel.
The apparatus of any preceding example, wherein a common distance between each horn along the longitudinal axis is λ/2.
A method, the method comprising: manufacturing two parts of a two-part
folded waveguide with horns having multiple surfaces that define a channel by at least: forming a first part of the waveguide such that the first part includes: a first surface from the multiple surfaces, the first surface having: a sinusoidal shape that folds back and forth about a longitudinal axis that extends in a longitudinal direction through the channel; and a plurality of radiation slots, each of the radiation slots in a shape of a horn that forms a respective hole extending through the first surface and into the channel; at least one second surface from the multiple surfaces, the second surface being perpendicular to the first surface to define an upper half of walls of the channel that are normal to the first surface; and a first feature at one end of the waveguide, the first feature defining a portion of a rectangular opening in the longitudinal direction and through to the channel; forming a second part of the waveguide such that the second part of the waveguide includes: a third surface from the multiple surfaces, the third surface having the same sinusoidal shape as the first surface; at least one fourth surface from the multiple surfaces, the fourth surface being perpendicular to the third surface, the fourth surface defining a lower half of the walls of the channel; and a second feature at the same end of the waveguide as the first feature, the second feature defining a remaining portion of the rectangular opening that is not defined by the first feature; and arranging the second part of the waveguide to be adjacent to and parallel with the first part of the waveguide by: orientating the first part of the waveguide with the second part of the waveguide to align the first feature of the first part of the waveguide with the second feature of the second part of the waveguide; and aligning the upper half of the walls of the channel that are normal to the first surface of the first part of the waveguide with the lower half of the walls of the channel that are perpendicular to the third surface to cause the sinusoidal shape of the first and second parts of the waveguide to be aligned in parallel.
The method of any preceding example, wherein arranging the second part of the waveguide to be adjacent to and parallel with the first part of the waveguide comprises evenly separating the first part of the waveguide from the second part of the waveguide by a layer of material measuring less than twenty percent of a total size of the channel defined by the lower and upper halves of the walls.
The method of any preceding example, wherein forming each of the first part and the second part of the waveguide comprises using injection molding.
The method of any preceding example, further comprising: securing the first part of the waveguide to the second part of the waveguide in response to the arranging.
The method of any preceding example, wherein securing the first part of the waveguide to the second part of the waveguide comprises securing with a fastener maintains the first and second parts of the waveguide in a parallel arrangement.
The method of any preceding example, wherein a fastener comprises at least one of a plastic fastener or a metal fastener.
The method of any preceding example, wherein securing the first part of the waveguide and the second part of the waveguide comprises securing with causing an adhesive bond between the second surface and the fourth surface.
The method of any preceding example, wherein causing the adhesive bond comprises using a dielectric, an epoxy, a glue, or a double-sided tape.
While various embodiments of the disclosure are described in the foregoing description and shown in the drawings, it is to be understood that this disclosure is not limited thereto but may be variously embodied to practice within the scope of the following claims. From the foregoing description, it will be apparent that various changes may be made without departing from the spirit and scope of the disclosure as defined by the following claims.
The use of “or” and grammatically related terms indicates non-exclusive alternatives without limitation unless the context clearly dictates otherwise. As used herein, a phrase referring to “at least one of” a list of items refers to any combination of those items, including single members. As an example, “at least one of: a, b, or c” is intended to cover a, b, c, a-b, a-c, b-c, and a-b-c, as well as any combination with multiples of the same element (e.g., a-a, a-a-a, a-a-b, a-a-c, a-b-b, a-c-c, b-b, b-b-b, b-b-c, c-c, and c-c-c or any other ordering of a, b, and c).
This application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application No. 63/188,265, filed May 13, 2021, the disclosure of which is hereby incorporated by reference in its entirety herein.
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