Terahertz waveguide comprising an outer copper layer laminated with an inner dielectric layer to form a rolled guide tube which is encased by a support tube
11978943 ยท 2024-05-07
Assignee
Inventors
Cpc classification
H01P3/16
ELECTRICITY
H01P5/022
ELECTRICITY
International classification
H01P11/00
ELECTRICITY
Abstract
An overmoded dielectric-lined waveguide, particularly for the 0.03 to 3 terahertz frequency range, is disclosed with performance advantages relative to prior dielectric-lined waveguides, cost and size advantages relative to corrugated waveguides, and with coupling, bandwidth, and cost advantages relative to micro-structured-fiber waveguides. The waveguide comprises a single-clad flexible microwave laminate rolled into a cylinder with said copper surface on an outside of said guide tube and said dielectric surface on an inside of said guide tube. The rolled laminate is supported inside a metal tube. The same method of achieving the structure needed for efficient guiding of HE.sub.11 mode may be applied to a conical tube to make a low-cost efficient overmoded tapered waveguide transition for the 0.03-3 THz range.
Claims
1. A waveguide for the transmission of radiation at nominal frequency f.sub.0, comprising: a laminate comprising a single copper layer bonded to a dielectric layer, said laminate formed into a guide tube with said copper layer on an outside of said guide tube and said dielectric layer on an inside of said guide tube, a support tube encasing said guide tube, said support tube further characterized as having a minimum inside diameter d.sub.i greater than 2?, where ? is the free-space wavelength at said frequency f.sub.0.
2. The waveguide of claim 1 in which said dielectric layer is further characterized as having thickness to greater than ?.sub.d/6 and less than ?.sub.d/3, where ?.sub.d is the wavelength in said dielectric layer at said frequency f.sub.0.
3. The waveguide of claim 1 in which said dielectric layer has a tensile strength, and in which said dielectric layer is further characterized as having a dielectric loss tangent less than 0.003 at 30 GHz, a dielectric constant less than 3, and having an elastic modulus less than 100 times said tensile strength.
4. The waveguide of claim 1 in which said frequency f.sub.0 is greater than 30 GHz and less than 3000 GHz.
5. The waveguide of claim 1 in which said guide tube has a first end and a second end, and in which said guide tube is further characterized as having a maximum inside diameter d.sub.1 at said first end, a minimum inside diameter d.sub.2 at said second end, and a taper angle ?, said taper angle further characterized as being less than 10?, said diameter d.sub.2 further characterized as being less than said diameter d.sub.1 and greater than a diameter d.sub.1/2.
6. The waveguide of claim 1 in which said guide tube has an inner surface, and in which said guide tube is further characterized as being of a work-hardenable alloy with said inner surface sanded and lubricated.
7. The waveguide of claim 1 wherein the dielectric layer is a low-loss dielectric.
8. The waveguide of claim 1 wherein the dielectric layer is substantially PTFE.
9. The waveguide of claim 1 in which said support tube is further characterized as comprising two semi-cylinder support tubes, each having a semi-cylindrical concave surface of radius suitable for encasing and supporting the guide tube, that together encase and support the guide tube.
10. The waveguide of claim 9 in which the two semi-cylinder support tubes each have a round outer profile or a square outer profile.
11. The waveguide of claim 1 in which said copper layer has thickness not less than 11 microns and not greater than 70 microns.
12. A method for use with a radiation at nominal frequency f.sub.0, the method carried out by an apparatus comprising a laminate comprising a single copper layer bonded to a dielectric layer, said laminate formed into a guide tube with said copper layer on an outside of said guide tube and said dielectric layer on an inside of said guide tube, a support tube encasing said guide tube, said support tube further characterized as having a minimum inside diameter d.sub.i greater than 2?, where ? is the free-space wavelength at said frequency f.sub.0, the method comprising passing said radiation at the nominal frequency f.sub.0 into a first end of said guide tube and making use of said radiation after said radiation is emitted from a second end of said guide tube.
13. The method of claim 12 wherein the dielectric layer is a low-loss dielectric.
14. The method of claim 12 wherein the dielectric layer is substantially PTFE.
15. A method for use with radiation at nominal frequency f.sub.0, and with a laminate comprising a single copper layer bonded to a dielectric layer, the method comprising: forming said laminate into a guide tube with said copper layer on an outside of said guide tube and said dielectric layer on an inside of said guide tube, and encasing said guide tube within a support tube; said support tube characterized as having a minimum inside diameter d.sub.i greater than 2?, where ? is the free-space wavelength at said frequency f.sub.0.
16. The method of claim 15 wherein the dielectric layer is a low-loss dielectric.
17. The method of claim 15 wherein the dielectric layer is substantially PTFE.
18. The method of claim 15 further comprising the step of providing a lubricant between the guide tube and the support tube.
19. The method of claim 15 further comprising the step of sanding an inner surface of the guide tube.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
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(12) The laminate layers 101, 102 forms the guide tube and could be any of the commonly available low-loss flexible microwave copper-clad laminates, in which the dielectric is substantially PTFE, possibly with some glass or ceramic reinforcing fibers. Examples of suitable laminate product lines include Polyflon CUFLON (a microwave substrate comprising PTFE coupled with a plating process), Rogers DUROID (a filled PTFE), and Taconic TLY5 (a composite of PTFE with a lightweight woven fiberglass). Various grades of these materials have dielectric constants (permittivity) below 3 with loss tangent below 0.003 at 30 GHz, and some (at least those with pure PTFE dielectric) have loss tangent below 0.002 at 400 GHz. These laminates are available in various dielectric thicknesses, in some cases down to 0.025 mm, and even thinner dielectric may be possible for pure PTFE. In principle, other low-loss flexible dielectrics such as HDPE, TPX, and TOPAS (a cyclic olefin copolymer) could also be used, but copper-clad laminates utilizing such are not commercially available.
(13) The laminates are normally supplied with copper cladding on both surfaces, in which case the copper cladding would need to be etched from one side to obtain the needed single-clad laminate. The copper claddings are typically 11-70 ?m thick (0.33 oz/ft.sup.2 to 2 oz/ft.sup.2), any of which is suitable, as i the thickness need only be more than 4?, where ? is the rf skin depth, ?0.4 ?m in copper at 30 GHz. Preferably the dielectric substrate should have elastic modulus less than 100 times its tensile strength to have the flexibility needed to be readily formed into a cylinder of sufficiently small diameter when single-clad.
(14) The support tube 103 would typically be either soft copper or a hard copper alloy, depending on whether or not some flexibility was desired. Either material readily permits soldering to connector flanges 201, 202 which may be desired at the ends, as illustrated in
(15) The alert reader immediately sees the similarity between the instant invention and the coated hollow flexible waveguides by Harrington et al., but there are a number of crucial inventive differences that substantially improve RF performance at frequencies to at least 2.5 THz with available microwave laminates. As noted earlier, the prior-art polystyrene solution precipitation method has not permitted deposition of coatings of the thickness and quality needed for satisfactory waveguide performance below ?1 THz. Moreover, the loss tangent of PS is typically 5 to 20 times that of PTFE in the 0.1 to 3 THz range, depending on impurities and polymerization details.
(16) The more obvious alternative to the instant invention of simply forming an un-clad dielectric sheet into a cylinder and inserting that into a metal tube results in a variable air gap layer between the dielectric and the metal tube that leads to extremely high E fields in the dielectric and extremely high H fields on the surface of the metal tube at all the micro contact points between the dielectric lining and the metal tube. The surface currents in the metal are the dominant loss mechanism in all the simulated cases reported herein. Those losses are quadratic with H field and thus are much greater when the H surface field is less uniform. The instant invention eliminates virtually all of those high-loss contact points (other than the few that remain at the edges of the copper-clad laminate) and thus greatly reduces losses and mode conversions that surface irregularities can cause.
(17) Simulations using state-of-the-art highly validated commercial microwave software (in particular, the time-domain software CST, currently available from Dassault Systemes) show that the optimum lining thickness t.sub.d, at least for waveguide diameters in the range of 3-10?, is ??.sub.d/4, where ?.sub.d is the wavelength at f.sub.o in the lining, though excellent performance is also often seen with t.sub.d as small as ?.sub.d/6 or as large as ?.sub.d/3.
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(19) Note that the loss for HE.sub.11 for the above case (with about an octave usable range) is over two orders of magnitude smaller than the 25 dB/m expected in fundamental-mode round waveguide at 400 GHz. The dielectric thickness in the case of
(20) In another simulation, the same waveguide as simulated for
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(22) The TE.sub.11 mode THz source 401 excites the short fundamental-mode cylindrical waveguide on the left. Since loss for HE.sub.11 mode in lined waveguides is about half of that for TE.sub.11 mode and loss is lower in waveguides of larger diameter, the first step is to convert the TE.sub.11 mode to HE.sub.11 mode of substantially larger diameter with a quasi-Gaussian profile. This is done in spline horn 402, according to the prior art, which converts some of the input TE.sub.11 mode to the needed TM.sub.11 mode component of appropriate relative amplitude and phase. For the exemplary case simulated here, a published 33-45 GHz spline horn optimization [Zeng, et al., 2010] was scaled down by a factor of ?10 for 300-400 GHz operation, with relative dimensions approximately as shown. The spline horn is followed by a large overmoded cylindrical waveguide 403, of ID matching the aperture of the spline horn, that guides the beam over most of the path length in the example cases simulated.
(23) A first conical down-taper transition 404 then reduces the beam diameter to match the diameter of mid-sized overmoded cylindrical waveguide 405, which guides the beam at higher intensity over most of the remaining path. A second conical down-taper transition 406 then reduces the beam diameter to match the diameter of small overmoded cylindrical waveguide 407, which guides the beam at yet higher intensity over the remaining distance to the sample 408. Small defects, in the form of 0.2-mm edge radii on the components at the junctions and 0.07 mm gaps extending radially 0.3 mm into the metal wall and 0.1 mm misalignments, were included in the numerical model at the junctions between each component to approximate what might be seen from typical manufacturing and assembly errors.
(24) Simulated transmission spectra for the above described 345-GHz case with classic smooth hollow metal waveguides and transitions are shown in
(25) Simulated transmission spectra for the same case, except now with all the overmoded waveguides and tapered transitions lined with PTFE 0.15 mm thick (?.sub.d/4 at 345 GHz), are shown in
(26) The laminate-lined conical tapered transition, as illustrated in
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(28) A low-loss waveguide optimized for 2 THz (?=0.15 mm) could be made using the thinnest PTFE-substrate laminate currently commercially available (0.025 mm) inside a support tube of 1 to 2 mm ID. Scaling from the results in
(29) A low-loss waveguide optimized for 32 GHz (?=9.4 mm) could be made using a PTFE-substrate laminate with 1.59-mm dielectric thickness (a common commercially available size) inside a support tube as small as 20 mm ID.
(30) Composite substrates with somewhat higher dielectric constants than PTFE are available with loss tangents below 0.003 at 30 GHz and possibly even up to 200 GHz, making such suitable for dielectric linings at frequencies in the 30-200 GHz range. However, they also have substantially lower flexibility, making them more difficult to use for cases with d.sub.i/t.sub.d<30, while the pure PTFE substrates can readily be used with d.sub.i/t.sub.d as small as 10, or even as small as 7 with suitable procedures. Forming the laminate into the cylindrical or conical guide tube is generally easier if the copper thickness is greater than t.sub.d/20 but less than t.sub.d/3.
(31) As the support tube can easily be quite thin, the OD of a 600 GHz laminate-lined waveguide, with d.sub.i=4?.sub.d could be as small as 2.2 mm, which is about a quarter the OD that seems practical for a corrugated waveguide at 600 GHz.
(32) The basic manufacturing concept illustrated previously in
(33) A manufacturing alternative is shown in
(34) The outer surface of the support semi-tubes need not be round. For very small waveguides, it may be preferable to produce the support semi-tubes by milling a concave cylindrical surface onto one side of a rectangular strip, as seen in
(35) The alert reader will have no difficulty devising myriad obvious improvements and variations to the invention set forth herein, all of which are intended to be encompassed with the claims which follow.
REFERENCES
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