This application claims priority to and is a 35 U.S.C. § 371 U.S. National Stage Application of International Application No. PCT/EP2023/051361, entitled “WAVEGUIDE TERMINATION STRUCTURE AND METHOD OF MANUFACTURE”, filed Jan. 20, 2023, which claims priority to European Application No. 22183816.2, entitled “WAVEGUIDE TERMINATION STRUCTURE AND METHOD OF MANUFACTURE”, filed Jul. 8, 2022, the contents of each being incorporated by reference herein in its entirety.
The present invention relates to waveguide termination, and particularly to the structure and method of manufacture of a radio-frequency (RF) load for waveguide terminations.
In the field of satellite communications, in which electromagnetic signals travel through waveguides, it is often necessary to terminate a waveguide to prevent reflection of unwanted energy by the waveguide interface.
The packaging of waveguide terminations within a satellite payload presents some significant challenges. The terminations experience extreme conditions during operation, particularly high thermal flux when in use as an RF power absorber. For example, a termination must be able to tolerate the sudden application of an RF field and hence incur a significant thermal shock. The termination must also provide electrical isolation from the inside to outside in order to prevent unwanted signal radiation and, by reciprocity, must provide shielding from external signals. The termination must also be able to tolerate rapid de-pressurisation and the harsh vibration environment experienced during the ascent of the satellite during its launch phase, particularly at lift-off. The termination is subjected to the extreme variations in temperature that are experienced in space, particularly when the satellite passes into solar eclipse during its orbit and must be able to tolerate the twice-daily thermal shock experienced by the satellite crossing the solar terminator during its operational lifetime. This equates to approximately 11,000 cycles for a typical 15-year geostationary mission and up to 60,000 cycles for satellites operating in polar or highly elliptical orbits.
As shown in
It is an aim of embodiments of the present invention to improve the ability of a waveguide termination to absorb incident RF energy. This is achieved by providing one or more load cells, for one or more corresponding waveguide terminations, that are integral with the structure by which they are to be fixed to the one or more waveguide terminations. Embodiments of the present invention can make use of additive 20 manufacturing (AM) to manufacture such integral structures, referred to herein as ‘RF loads’.
A significant advantage of embodiments of the present invention is that there is not a need to use a thermally conductive adhesive to secure the position of the load cell, in contrast to conventional configurations. In addition to improving performance of the RF load, the complexity of its manufacture is reduced. Further advantages will become apparent from the following description of the embodiments of the present invention.
According to an aspect of the present invention there is provided a radio frequency, RF, load for a waveguide termination, comprising a load cell for absorbing incident RF energy, a backing plate configured to absorb the RF energy propagating through the load cell, wherein the backing plate is further configured to fix the load cell to a housing of the waveguide termination, and wherein the backing plate is integral with the load cell.
The load cell may taper along the longitudinal axis.
The backing plate and the load cell may share a plane and wherein the load cell is tapered to the shared plane.
The load cell and backing plate may comprise a ceramic material.
The ceramic material may be silicon carbide.
The RF load may further comprise at least one additional load cell, wherein the at least one additional load cell is integral with the backing plate.
According to another aspect of the present invention there is provided a waveguide termination for terminating a radio frequency, RF, waveguide comprising the above RF load, a housing comprising an interior channel to guide RF energy from the waveguide, and an interface for coupling to the waveguide, wherein the backing plate of the RF load is fastened to the housing such that the load cell is in communication with the interior channel.
According to another aspect of the present invention there is provided a multi-waveguide termination for terminating a plurality of radio frequency, RF, waveguides comprising the above RF load, a housing comprising a plurality of interior channels each arranged to guide RF energy from a respective waveguide, and an interface for coupling to the plurality of waveguides, wherein the backing plate of the RF load is fastened to the housing such that each respective load cell is in communication a respective interior channel.
According to another aspect of the present invention there is provided a waveguide termination comprising the above RF load, a housing comprising an interior channel to guide RF energy from the waveguide, and an interface for coupling to the waveguide, wherein the RF load is integral with the housing, arranged such that the load cell is in communication with the interior channel.
According to another aspect of the present invention there is provided a multi-waveguide termination comprising the above RF load, a housing comprising a plurality of interior channels each arranged to guide RF energy from a respective waveguide, an interface for coupling to the plurality of waveguides, wherein the RF load is integral with the housing, arranged such that the each respective load cell is in communication with a respective interior channel.
According to another aspect of the present invention there is provided a method of manufacturing a radio frequency, RF, load for a waveguide termination, the RF load comprising a load cell for absorbing incident RF energy, a backing plate configured to absorb the RF energy propagating through the load cell, wherein the backing plate is further configured to fix the load cell to a housing of the waveguide termination, the method comprising integrally forming the load cell with the backing plate.
According to another aspect of the present invention there is provided a method of manufacturing a radio frequency, RF, load for a multi-waveguide termination, the RF load comprising a plurality of load cells for absorbing incident RF energy, a backing plate configured to absorb the RF energy propagating through the load cells, wherein the backing plate is further configured to fix the load cells to a housing of the waveguide termination, the method comprising integrally forming the plurality of load cells with the backing plate.
According to another aspect of the present invention there is provided a method of manufacturing a waveguide termination, the waveguide termination comprising one or more load cells for absorbing incident RF energy, a backing plate configured to absorb the RF energy propagating through the load cells, a housing comprising one or more interior channels to guide RF energy from the waveguide, an interface for coupling to one or more waveguides, the method comprising integrally forming the one or more load cells with the backing plate and the housing, such that the respective one or more load cells are in communication with a respective interior channel.
The integral formation of the above methods may be achieved through additive manufacture.
The load cell 11 is constructed to absorb incident RF energy, and dissipate such energy into the backing plate 12. The backing plate 12 has a thickness configured in accordance with the expected incident energy level, and the dimensions of the housing a waveguide termination, described in more detail below.
In some embodiments, the load cell 11 has a longitudinal axis and the thickness of the load cell tapers, relative to a plane 14 shared by the backing plate 12 and the load cell 11.
In the embodiments illustrated, the tapered profile is uniform, the thickness of the load cell 11 reducing linearly with distance along the longitudinal axis. The tapered profile of the load cell 11 enables gradual, controlled absorption of RF energy by reducing reflection of the incident energy of the RF signal along the incident path by reducing the angle of incidence of the RF signal on the load cell 11 surface. In alternative embodiments, the load cell 11 may taper in a non-uniform manner along the longitudinal axis.
In some embodiments, such as that exemplified by
The integral formation of the load cell 11 and the backing plate 12 enables more effective absorption of RF energy compared to that which is possible using conventional load cells. This is achieved in particular by dissipating the thermal energy from the load cell 11 directly into the backing plate 12 without the need for a bonding material, while positioning of the load cell 11 is ensured via its integration with the backing plate 12.
The term ‘integral’, as referred to in relation to embodiments of the present invention, is used to refer to a single-body structure. The parts of the single-body structure can be defined as portions or regions of the single body. In contrast, a multi-body structure is referred to herein as being assembled from those parts as physically separate components. In
Formation of an RF load 10 comprising an integral load cell 11 and backing plate 12 can be achieved using various methods according to embodiments of the present invention, which lead to the production of a single-body structure. For example, additive manufacturing (AM) techniques, based on one or more configuration files, may be used in some embodiments in which the load 10 or termination is constructed through deposition of successive layers of material.
The load cell 11 may be composed of any suitable RF absorbing material. In some embodiments, the load cell 11 and backing plate 12 are composed of a ceramic material, and such ceramic materials are particularly suitable for high power applications in which a large amount of RF energy is to be absorbed. For example, such ceramic material may comprise silicon carbide. In alternative embodiments, the load cell 11 and backing plate 12 are composed of a resin, which is an effective material for lower power applications, and which provides structural robustness.
The housing 20 is arranged such that it houses an interior channel 21 for receiving incident RF energy. The load cell 11 is accommodated by the channel 21, to absorb incident RF energy in the channel 21. In the configuration illustrated in
The waveguide termination 30 further comprises an interface 35 and a closed end, at opposing ends of the interior channel of the housing 30. The interface comprises a fastening portion 36 and an opening 37. The fastening portion 36 is, in embodiments of the present invention, a flange arranged to be secured to a corresponding flange of a waveguide to be terminated, such that RF energy from the waveguide may propagate through the opening 37 into the interior channel of the waveguide termination 30. The closed end of the waveguide termination prevents further propagation of RF energy along the longitudinal axis of the waveguide termination 30.
The housing 32 of the waveguide termination 30, when coupled with the RF load 31, forms the waveguide termination 30 of
In some embodiments the width of the load cell 34 is arranged such that when inserted into the channel, it fills the width of the channel. In some embodiments, the load cell 34 does not extend along the entire length of the channel. In such embodiments, an area of the backing plate 33 from which the load cell 34 does not protrude is exposed to the channel and may be plated with an RF reflective material, such that RF energy is guided through the waveguide termination 30 until it reaches the load cell 34.
Each load cell 41 is constructed to absorb incident RF energy from a respective waveguide, and to dissipate such RF energy into the backing plate 42. In the embodiments represented by
The backing plate 42 is configured to fix the RF load 40 to a housing of a waveguide termination, such as the housing 50 shown in
The waveguide termination 60 may be fastened to a plurality of further waveguides, using the interface 65 of the housing. When fastened to a the plurality of further waveguides, the waveguide termination 60 is arranged such that RF energy propagating in each of the further waveguides may pass through a respective one of the plurality of openings 66 of the housing 62, into the termination 60 and subsequently be absorbed by a respective one of the plurality of load cells 64. In so doing, a plurality of waveguides are terminated. Further, as the backing plate 63 is integral with the plurality of load cells 64, the load cells 64 are able to dissipate absorbed RF energy into the backing plate 63, without using a thermal adhesive as an intermediary.
The waveguide termination 60 further comprises an interface 65 and a closed end, at opposing ends of each channel. The interface 65 comprises a fastening portion 67 and a plurality of openings 66. The fastening portion 67 is arranged to be secured to a plurality of further waveguides such that a plurality of signals may propagate through a respective one of the plurality of openings into the waveguide termination 60.
It is noted that although
The provision of multiple openings 66 within a single fastening portion or flange enables uniform coupling of each of a plurality of waveguides to the waveguide termination 60 via a coupling mechanism to each of the plurality of waveguides.
In the embodiment of
In the arrangement of
It is noted that although
According to further embodiments of the present invention, there is provided a method of manufacturing an RF load for a waveguide termination, as described with reference to
According to further embodiments of the present invention, there is provided a method of manufacturing an RF load for a waveguide termination, as described with reference to
According to further embodiments of the present invention, there is provided a method of manufacturing a waveguide termination according to
In some embodiments, the integral formation of the one or more load cells, the backing plate and the housing employs a ceramic material to define the overall structure of the waveguide termination. A further step of coating the interior of the one or more channels within the housing with reflective material, such as metal, is performed in order to provide the channel with the ability to guide incident RF energy to the load cell. This coating step may be part of an additive manufacturing process, or may alternatively be a deposition process.
It will be appreciated that a number of modifications to the embodiments described above are possible which fall within the scope of the claims. For example, the embodiments are described in relation to termination of waveguides having a rectangular cross-section, but it is also possible to apply the principles disclosed herein to waveguides of other shapes, such as elliptical cross-sections, using appropriately-shaped backing plates and load cells. The specific nature of the load cell and backing plate will be dependent upon particular applications and the nature of the waveguide to be terminated, and the RF energy to be absorbed.
Number | Date | Country | Kind |
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22183816 | Jul 2022 | EP | regional |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2023/051361 | 1/20/2023 | WO |
Publishing Document | Publishing Date | Country | Kind |
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WO2024/008339 | 1/11/2024 | WO | A |
Number | Name | Date | Kind |
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20180159236 | Kroening | Jun 2018 | A1 |
20200274218 | Ushijima et al. | Aug 2020 | A1 |
Number | Date | Country |
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15 16 800 | Jan 1970 | DE |
S57-41005 | Mar 1982 | JP |
H05-218708 | Aug 1993 | JP |
H10-107507 | Apr 1998 | JP |
Entry |
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Beuerle Bernhard et al: “Micromachined Waveguides with Integrated Silicon Absorbers and Attenuators at 220-325 GHz”, 2018 IEEE/MTT-S International Microwave Symposium—IMS, IEEE, Jun. 10, 2018 (Jun. 10, 2018), pp. 579-582, XP033388028, DOI: 10.1109/MWSYM.2018.8439364. |
Mar. 24, 2023 Search Report issued in International Patent Application No. PCT/EP2023/051361; 4 pp. |
Mar. 24, 2023 Written Opinion of the International Searching Authority issued in International Patent Application No. PCT/EP2023/051361; 10 pp. |
International Preliminary Report on Patentability dated Jan. 23, 2025 in PCT/EP2023/051361. |
Number | Date | Country | |
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20250174867 A1 | May 2025 | US |