Abstract
The invention relates to a method of manufacturing technical radio frequency functional structures comprising the steps of providing a base body determining the shape of the functional structure and applying an electrically conductive layer to the shape-determining base body by means of wetting the base body with a dispersion containing microparticles and/or nanoparticles.
Claims
1. A method of manufacturing technical radio frequency functional structures, the method comprising the steps: providing a base body determining the shape of the functional structure; applying an electrically conductive layer to the shape-determining base body by means of wetting the base body with a dispersion containing microparticles and/or nanoparticles.
2. A method in accordance with claim 1, characterized in that the step of coating comprises a single or multiple immersion of the base body into a dipping bath, in particular an ultrasound bath, containing the dispersion.
3. A method in accordance with claim 1, characterized in that the step of coating provides a treatment of the base body in an aerosol chamber to apply the dispersion to the base body.
4. A method in accordance with claim 1, characterized in that the step of coating takes place by pouring dispersion over the base body.
5. A method in accordance with claim 1, characterized in that the step of coating takes place by spraying the base body with the dispersion.
6. A method in accordance with one of the preceding claims, characterized in that the microparticles and/or nanoparticles are particles of gold and/or silver and/or copper and/or aluminum and/or particles of other substances that form conductive layers.
7. A method in accordance with one of the preceding claims, characterized in that, after the coating, a thermal post-treatment of the base body takes place, in particular by sintering, ultraviolet treatment, supply of hot air, or infrared irradiation.
8. A method in accordance with one of the preceding claims, characterized in that the functional structure is a radio frequency line, in particular a waveguide, or an antenna, in particular a horn antenna or helix antenna, or a filter, or a resonator, or a coupler, or any other passive RF part.
9. A method in accordance with one of the preceding claims, characterized in that the base body is designed such that base body material is only present where it is necessary for the mechanical strength and/or where a conductive surface is necessary to ensure the technical radio frequency function, in particular such that walls are provided with apertures or are fully or partially designed as helices or lattices.
10. A method in accordance with one of the preceding claims, characterized in that the dispersion has a water base and/or a base of one or more solvents and/or additional adhesives.
11. A method in accordance with one of the preceding claims, characterized in that the base material consists of or comprises ceramics or plastic or metal.
12. A method in accordance with one of the preceding claims, characterized in that the base body is manufactured by means of an additive process, in particular SLA 3D printing, or plastic injection molding.
13. A method in accordance with one of the preceding claims, characterized in that the surface of the base body is pre-treated before the coating.
Description
[0023] Further advantages and properties of the invention will be presented in the following with reference to some examples for radio frequency components that were manufactured by means of the method in accordance with the invention. There are shown:
[0024] FIG. 1 a helix antenna manufactured by means of the method in accordance with the invention;
[0025] FIG. 2 a rectangular horn antenna manufactured by means of the method in accordance with the invention;
[0026] FIG. 3 a ridged horn antenna manufactured by means of the method in accordance with the invention;
[0027] FIG. 4 a slotted waveguide antenna manufactured by means of the method in accordance with the invention;
[0028] FIG. 5 a further slotted waveguide antenna manufactured by means of the method in accordance with the invention;
[0029] FIG. 6: a waveguide manufactured by means of the method in accordance with the invention,
[0030] FIG. 7 a more complex system composed of radio frequency components manufactured by means of the method in accordance with the invention comprising waveguides, waveguide bends, and a horn antenna; and
[0031] FIG. 8 a waveguide coupler manufactured by means of the method in accordance with the invention.
[0032] FIG. 1 shows a helix antenna 1a in accordance with the invention produced in accordance with the method in accordance with the invention. The helix antenna comprises a spiral helix 2 and a circular planar base surface 3 having a circular aperture 4 through which the lower end 5 of the helix is guided. The helix 2 and the base surface 3 are of a plastic base but in accordance with the invention an electrically conductive ink containing nanoparticles was applied to their surfaces. The helix 2 and the base surface 3 were first manufactured by means of an additive process such as SLA 3D printing for this purpose and were designed on the lower side of the base surface 3 as a radio frequency connector conforming to standards, for example as a waveguide flange.
[0033] FIG. 2 shows a horn antenna 1b that comprises a base body 2 and has a horn aperture with a rectangular cross-sectional portion. Inner walls 3 and outer walls 5 are coated as conductive in accordance with the method in accordance with the invention.
[0034] FIG. 3 shows a ridged horn antenna 1c as an example for a further passive radio frequency component. The component differs from the rectangular horn antenna 1b by a horn aperture having a round cross-sectional portion 2 and a transition 5 to a connection having a rectangular cross-section conforming to the standards. The inner wall of the horn aperture has a stepped or ridged surface 3. The manufacture of such a component can advantageously also be performed by means of the method in accordance with the invention.
[0035] FIG. 4 shows a slotted waveguide antenna 1d in accordance with the invention produced and coated as conductive in accordance with the method in accordance with the invention. The slotted waveguide antenna comprises a base body 2 having a rectangular cross-sectional portion on whose additive production apertures 4 remain in certain outer walls so that the intended function of the irradiation of an electromagnetic wave initially guided in the interior is achieved.
[0036] FIG. 5 in contrast shows a slotted waveguide antenna 1e in accordance with the invention, produced and coated as conductive in accordance with the method in accordance with the invention whose basic design is similar to that of the slotted waveguide antenna 1d, but with base body material only being built up where it is necessary (6) for the technical radio frequency function, which can likewise advantageously be performed by means of the method in accordance with the invention.
[0037] FIG. 6 shows a waveguide 1f for the radio frequency technology, produced in accordance with the method in accordance with the invention. The waveguide 1f substantially comprises a hollow body having a rectangular portion as the base body 2 whose inner walls 3 form the required hollow space for the guiding of electromagnetic waves. Base body material 6 is only built up in a similar manner to the slotted waveguide antenna 1e where it is required for the technical radio frequency function.
[0038] FIG. 7 shows a functional structure 1g that is designed in a similar manner to the waveguide 1f, but predefines a path bent in space for the electromagnetic waves. The one end is formed in accordance with a horn antenna 1b. The method in accordance with the invention for the electrically conductive coating of the functional structure is also used here.
[0039] FIG. 8 shows a coupler 1h for the radio frequency technology whose basic design is similar to two waveguides 1f contacting at their side walls. Apertures are functionally necessary between the two waveguides along these contact surfaces to enable an overcoupling of the electromagnetic waves from one waveguide into the other. All the other surrounding conductive structures are built up in a similar manner to the waveguide 1f where they are required for the guidance of the electromagnetic waves. The method in accordance with the invention for the electrically conductive coating of the surface of the coupler 1h is also used here.
