Longitudinally ridged quad polarizer feed
12512596 ยท 2025-12-30
Assignee
Inventors
Cpc classification
H01Q15/244
ELECTRICITY
International classification
H01P1/17
ELECTRICITY
H01P3/123
ELECTRICITY
Abstract
Longitudinally ridged quad polarizer feeds include a waveguide spanning a longitudinal axis between a feed port and an antenna port, with first ridge elements that span longitudinally from the feed port on first opposing walls of the waveguide and second ridge elements that span longitudinally from the feed port on second opposing walls of the waveguide. A polarization of a radio frequency signal transiting the waveguide is altered based at least on a difference in longitudinal lengths between the first ridge elements and the second ridge elements. These polarizers can be formed from a single workpiece using an injection molding technique, leading to a reduction in manufacturing complexity, cost, and mass.
Claims
1. An apparatus, comprising: a waveguide spanning a longitudinal axis between a feed port and an antenna port, wherein the feed port is arranged having a rectangular cross-sectional shape oriented on a diagonal alignment with respect to walls of the waveguide; first ridge elements that span longitudinally from the feed port on first opposing walls of the waveguide; second ridge elements that span longitudinally from the feed port on second opposing walls of the waveguide; wherein a polarization of a radio frequency signal transiting the waveguide is altered based at least on a difference in longitudinal lengths between the first ridge elements and the second ridge elements.
2. The apparatus of claim 1, wherein the radio frequency signal, when introduced to the waveguide at the feed port and having a linear polarization, is altered to have a circular polarization by at least the difference in longitudinal lengths between the first ridge elements and the second ridge elements.
3. The apparatus of claim 1, wherein a protrusion depth into the waveguide is established for the first ridge elements and the second ridge elements at the feed port to achieve an approximately equal power split for the radio frequency signal.
4. The apparatus of claim 3, wherein the first ridge elements taper down for a first associated protrusion depth to the first opposing walls of the waveguide at a longitudinal length shorter than the second ridge elements taper down for a second associated protrusion depth to the second opposing walls.
5. The apparatus of claim 1, wherein the walls of the waveguide, the first ridge elements, and the second ridge elements each comprise draft angles suitable for preventing undercuts using an injection molding manufacturing technique.
6. The apparatus of claim 5, wherein the injection molding manufacturing technique forms the walls of the waveguide, the first ridge elements, and the second ridge elements into a single piece of material.
7. The apparatus of claim 6, comprising: conductive plating applied to surfaces of the single piece of the material that contact the radio frequency signal.
8. The apparatus of claim 1, comprising: a horn element coupled to the antenna port and comprising a horn aperture.
9. The apparatus of claim 8, wherein the horn element, the walls of the waveguide, the first ridge elements, and the second ridge elements each comprise draft angles suitable for preventing undercuts using an injection molding manufacturing technique; and wherein the injection molding manufacturing technique forms the horn element, the walls of the waveguide, the first ridge elements, and the second ridge elements into a single piece of material.
10. The apparatus of claim 1, wherein the waveguide comprises a generally square cross-sectional shape, and wherein the feed port conforms to a standardized waveguide type.
11. A method, comprising: forming a waveguide having a generally square cross-section spanning a longitudinal axis between a feed port and an antenna port, wherein the feed port is arranged having a rectangular cross-sectional shape oriented on a diagonal alignment with respect to walls of the waveguide; forming first ridge elements having a first length spanning from the feed port and along the longitudinal axis on first opposing walls of the waveguide; forming second ridge elements having a second length spanning from the feed port and along the longitudinal axis on second opposing walls of the waveguide; and wherein a polarization of a radio frequency signal transiting the waveguide is altered based at least on a difference in lengths between the first ridge elements and the second ridge elements.
12. The method of claim 11, wherein a protrusion depth into the waveguide is established for the first ridge elements and the second ridge elements at the feed port to achieve an approximately equal power split for the radio frequency signal.
13. The method of claim 12, wherein the first ridge elements taper down for a first associated protrusion depth to the first opposing walls of the waveguide at a longitudinal length shorter than the second ridge elements taper down for a second associated protrusion depth to the second opposing walls.
14. The method of claim 11, wherein the walls of the waveguide, the first ridge elements, and the second ridge elements each comprise draft angles suitable for preventing undercuts using an injection molding manufacturing technique.
15. The method of claim 14, wherein the injection molding manufacturing technique forms the walls of the waveguide, the first ridge elements, and the second ridge elements into a single piece of material.
16. The method of claim 15, comprising: applying conductive plating to surfaces of the single piece of the material that contact the radio frequency signal.
17. The method of claim 11, further comprising: forming a horn element coupled to the antenna port and comprising a horn aperture.
18. The method of claim 17, wherein the horn element, the walls of the waveguide, the first ridge elements, and the second ridge elements each comprise draft angles suitable for preventing undercuts using an injection molding manufacturing technique; and wherein the injection molding manufacturing technique forms the horn element, the walls of the waveguide, the first ridge elements, and the second ridge elements into a single piece of material.
19. A horn antenna assembly, comprising: a polarizer comprising: a waveguide spanning a longitudinal axis between a feed port and an antenna port, wherein the feed port is arranged having a rectangular cross-sectional shape oriented on a diagonal alignment with respect to walls of the waveguide; first ridge elements that span a first length along the longitudinal axis from the feed port on first opposing walls of the waveguide; second ridge elements that span a second length along the longitudinal axis from the feed port on second opposing walls of the waveguide, wherein the first length is different than the second length; wherein a polarization of a radio frequency signal transiting the waveguide is altered based at least on a difference in lengths between the first ridge elements and the second ridge elements; and a horn antenna element comprising: a horn structure having a radio frequency aperture and a port, wherein the port is coupled to the antenna port of the polarizer.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Many aspects of the disclosure can be better understood with reference to the following drawings. While several implementations are described in connection with these drawings, the disclosure is not limited to the implementations disclosed herein. On the contrary, the intent is to cover all alternatives, modifications, and equivalents.
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DETAILED DESCRIPTION
(8) Polarizers can be deployed in microwave RF feed networks to convert polarizations of signals between linear and circular polarizations, and vice-versa. Linear vertical (or linear horizontal) polarization typically refers to a single electromagnetic signal propagating in a single plane along the direction of propagation, while circular polarization includes two linear components that are perpendicular to each other and having a phase difference of 90 (/2). Other polarizations are possible, such as elliptical. Often, feed networks with polarizers are coupled to horn antennas used for transmitting or receiving microwave communications. Large arrays of horn antennas, perhaps using hundreds of elements, can form electronically steerable arrays (ESAs) for satellite communications, terrestrial backbone communications, aircraft communications, radar systems, and other various applications. Conversion of polarizations of signals in such communication systems can enable more effective communications between endpoints having varied or unpredictable orientations. For example, it can be helpful to use circular polarization to communicate from a satellite to ground stations, aircraft, or vehicles.
(9) The examples discussed herein comprise polarizer feed structures and manufacturing techniques that generate circular polarization from single polarization in communication applications with a compact equipment envelope and with low mass. Moreover, injection molding techniques can be employed to achieve cost savings in large quantities, such as forming large arrays or horn antennas in ESAs. When injection molding or casting techniques are employed to manufacture polarizers or associated horn structures, draft angles are included to slope cross-sectional areas along certain axes. These draft angles are typically a requirement of the manufacturing tooling or process to prevent material overhangs or parallel surfaces in order to release the workpiece from a mold or die. A broadband quad-ridged polarizer feed is discussed herein that includes draft angles to facilitate injection molding without undercuts. Injection molding results in a significant mass decrease, fewer mechanical operations, and order of magnitude materials cost decrease when manufacturing large quantities of polarizer feeds or horn antennas with such polarizer feeds when compared to manufacturing using electrical discharge machining (EDM) or direct machining. While several examples cover portions of the RF microwave Ku band (approximately 12 to 18 GHz) or X band (approximately 8 to 12 GHz), it should be understood that other RF bands can be supported with accompanying scaling in size or geometry suitable to the corresponding wavelengths. Additionally the polarizer feeds and associated horn antennas can utilize a square aperture which provides higher spatial efficiency and performance in an array environment, but circular, triangular, hexagonal, or irregular horn antennas can be employed using similar techniques.
(10) Materials employed for the elements of the polarizers or horn antennas or any of the quad-ridged polarizer feeds discussed herein can include any injection-moldable material. Examples include plastics, polymers, carbon composites, polyamide, acrylic, polycarbonate, polyoxymethylene, polystyrene, acrylonitrile butadiene styrene (ABS), polypropylene, polyethylene, polyurethane, thermoplastic rubber, including combinations thereof. Additionally, various additives can be included in the injected material, such as stabilizers, glass or organic fibers, structural elements, lubricants, mold release agents, or other additives. The material can be injected via at least one port into a mold or die which forms the shapes and cavities of the associated elements. Once formed, conductive surface treatments are typically applied at least to surfaces in contact with RF signals. These conductive surface treatments include various platings, including conductive materials, metallic substances, metals, metal alloys, and the like, such as aluminum, copper, silver, gold, or other similar metals or associated combinations.
(11) Turning now to a first example polarizer feed,
(12) Quad polarizer feed 105 comprises two portions 110 and 120. Portion 110 includes waveguide 111 comprising a cavity surrounded by walls forming a generally square waveguide shape along a longitudinal axis. Portion 110 also includes external port 112, internal port 113, and waveguide wall ridges 115-118. Portion 120 includes interfacing elements that couple internal port 113 to port 121, which can then couple to other RF elements, such as further waveguides that might feed quad polarizer feed 105. Port 121 can also be referred to as a feed point or feed ports, depending on the configuration. Ports 112-113 and 121 comprise apertures that can have a throat/opening width which depends on the particular wavelength of RF communications. Draft angle is shown for walls of waveguide 111, and this angle can be reflected in other features of quad polarizer feed 105, such as internal ridge features and waveguide interface features. While a can be approximately 1, the particular angle used can be selected based on the manufacturing process and typically is minimized for a particular process. Also, the example draft angle does not need to be equal throughout the workpiece, but is typically selected to maintain mirror symmetry along the longitudinal axis.
(13) Waveguide wall ridges 115-118 are included in waveguide 111. Waveguide wall ridges 115-118 are located on top/bottom walls and left/right (side) walls of waveguide 111 and centered on the corresponding waveguide walls. While waveguide wall ridges 115-118 are not necessary to be centered on the associated walls of waveguide 111, the effectiveness of the ridges can be affected by placement away from center. Waveguide wall ridges 115-118 extend from internal port 113 of waveguide 111 along a longitudinal axis of waveguide 111 for selected lengths. Side ridges 115-116 can have a corresponding length L1, and top/bottom ridges 117-118 can have a corresponding length L2. Typically, L1 and L2 are selected to be a different length, which can be selected to achieve to a target phase shift and target power split among propagation modes transiting waveguide 111, such as a 90 phase shift and equal power split between horizontal/vertical propagation modes. A generally trapezoidal shape with tapers, fillets, or chamfers along longitudinal edges is employed for waveguide wall ridges 115-118 in
(14) Portion 120 of quad polarizer feed 105 comprises interfacing elements that couple internal port 113 of waveguide 111 to other RF elements, such as further waveguides which might feed waveguide 111 or receive signals from waveguide 111. Specifically, portion 120 includes port interface section 122 and waveguide interface flange 123. Portion 120 can receive or transfer RF signals transiting through connecting waveguides (not shown), as well as act as transformer or impedance match segments. Port interface section 122 and waveguide interface flange 123 can be employed to transition internal port 113 to a standardized waveguide type or size, such as WR-34 or WR-42, or to provide a structural mount for quad polarizer feed 105. Portion 120 can comprise a wavelength () transformer to a rectangular waveguide (e.g. WR-34 or WR-42). Other waveguide types can couple to waveguide interface flange 123, such as ridged waveguides (e.g. WRD-580).
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(17) View 200 shows the stepped features of top/bottom waveguide wall ridges 117-118, notably steps 217-219 for ridge 117. This series of the corresponding steps reduce a height of waveguide wall ridges 117-118 from an initial height at internal port 113 to ultimately merge with the associated surfaces (ceiling/floor) of waveguide 111. The features of the steps on all waveguide wall ridges are sloped to accommodate the selected draft angles. The quantity, length, and configuration of the step features on all waveguide wall ridges can be selected based on application and target performance characteristics for quad polarizer feed 105.
(18) L1 comprises a length short enough to maintain a target power split and impedance properties of quad polarizer feed 105. For example, length L1 and the quantity or configuration of steps 217-219 can be selected to transition to the wall of waveguide 111 after a target power split is achieved by the waveguide wall ridges (i.e. equal power split between horizontal/vertical propagation modes). The power split is achieved by at least in part by physical symmetry among the four ridges proximate to internal port 113, and then this symmetry is broken along the longitudinal length of waveguide 111 (e.g. at L1). In this example, an equal power split is achieved by having all four waveguide wall ridges run to and be flush with the backwall of waveguide 111 at internal port 113 and begin at approximately equal depths into the cavity volume of waveguide 111 (referred to as height above). This configuration can be seen in end view 201 where ridges 115-118 each extend to similar depths from the walls towards the centerline of waveguide 111.
(19) Side waveguide wall ridges 115-116 extend longitudinally until length L2 to establish a difference in longitudinal length among ridges, namely between top/bottom waveguide wall ridges at L1 and side waveguide wall ridges 115-116 at L2. Thus, a first set of opposing waveguide wall ridges is established by ridges 115-116 and a second set of opposing waveguide ridges is established by ridges 117-118. The difference in longitudinal length between the two opposing sets of waveguide wall ridges generates a target phase shift between propagation modes (i.e. 90 phase shift between horizontal/vertical propagation modes). A first set of two opposing ridges (117-118) step down after a launch section leaving a second set of opposing ridges (115-116) to generate a phase shift in a signal transiting waveguide 111. In this manner, the 90 phase shift for cross-polarization (CP) is generated. This use of the two sets of opposing waveguide ridges avoids the need for corrugations or dimples along the length of waveguide 111. To further describe the waveguide wall ridges, all four side ridges establish a power split and impedance properties at internal port 113, while one opposing set of wall ridges continues for a longer longitudinal length than the other set of opposing wall ridges before tapering down to the wall. When internal port 113 is driven (via port 121) with a single propagation mode, two modes are resultantly established at external port 112, each mode having a 90 difference in phase. L2 can thus be selected to achieve this target phase shift, at which point side waveguide wall ridges 115-116 terminate by transitioning to the walls of waveguide 111.
(20) View 201 shows a rear port, comprising internal port 113 and feed port 121, having rectangular cross-sectional configurations oriented on a diagonal or 45 off-axis with respect to the square shape of waveguide 111. When being driven with a signal in a transmit operational mode, internal port 113 thus drives waveguide 111 at 45 off-axis. Internal port 113 and feed port 121 also step up the physical cavity size from a feed waveguide (not shown) to the size of waveguide 111. Clocking the rear port 90 results in a switch from right-hand circular polarization (RHCP) only to left-hand circular polarization (LHCP) only (or vice versa).
(21) The enhanced structures and features of quad polarizer feed 105 have the flexibility to be manufactured using any desired manufacturing approach, including electrical discharge machining (EDM), direct machining, or injection molding. However, the specific requirements of injection molding tooling, namely use of draft angles, can pose challenges for other waveguides and feeds. When an injection molding or casting process is employed to form quad polarizer feed 105, waveguide 111, external port 112, internal port 113, waveguide wall ridges 115-118, elements 122-123, and associated cavities, each comprise geometry incorporating draft angles corresponding to the selected molding or casting technique, and can be formed from a single workpiece or molded piece of material. In some manufacturing scenarios, section a-a (seen in
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(24) Horn antenna assembly 450 thus comprises a square multi-mode horn integrated with a polarizer for improved aperture efficiency, reduced length and broad performance bandwidth. Quad polarizer feed 410 can be an example of quad polarizer feed 105 when coupled to a horn element. While the specific frequency range suitable for horn antenna assembly 450 can vary, one example is shown in
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(26) Graph 500 illustrates performance optimized for 5 percent bandwidth of the microwave K band. Graph 500 includes a vertical axis indicating axial ratio (in dB) and a horizontal axis indicating frequency in GHz. Curve 501 in graph 500 shows a <0.10 dB axial ratio over a 5% bandwidth. This indicates the quad polarizers discussed herein achieve outstanding narrowband performance. Graph 600 illustrates performance optimized for 18 percent bandwidth of the microwave K band. Graph 510 includes a vertical axis indicating axial ratio (in dB) and a horizontal axis indicating frequency in GHz. Curve 511 shows performance of a quad polarizer exhibiting a third null in axial ratio. This third null indicates the quad polarizers discussed herein achieve broadband performance competing with other approaches, such as corrugated polarizer approaches. The quad polarizer topology discussed herein has a phase differential which crosses 90 three times which leads to a highly desirable third null in the axial ratio over frequency. Resulting performance competes favorably with even that of the complex and expensive traditional polarizer approaches. When compared to other low-complexity approaches such as a pinch polarizer, the quad polarizers discussed herein can achieve 3 the bandwidth and 8 better axial ratio along with a greater than 6 dB improvement in return loss. These performance improvements also are achieved in a smaller physical package than most other polarizers. The use of injection molding techniques can reduce the mass by a factor of two as compared to EDM or direct machined parts.
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(28) The square horn employed for the performance characteristics in
(29) Graph 600 includes a vertical axis indicating axial ratio (in dB) and a horizontal axis indicating frequency in GHz. Curve 601 in graph 600 shows axial ratio performance over a selected frequency range. Graph 610 includes a vertical axis indicating return loss (in dB) and a horizontal axis indicating frequency in GHz. Curve 611 in graph 610 shows return loss performance over the selected frequency range. Graph 620 includes a vertical axis indicating aperture efficiency (in dB) and a horizontal axis indicating frequency in GHz. Curve 621 in graph 620 shows aperture efficiency performance over the selected frequency range. Thus, the graphs in
(30) It should be understood that various communication bands and frequencies can be employed for the equipment discussed herein, with corresponding geometry scaling to suit the frequency ranges. For example, the equipment can support a frequency range corresponding to the Institute of Electrical and Electronics Engineers (IEEE) bands of S band, L band, C band, X band, Ku band, Ka band, V band, W band, among others, including combinations thereof. Other example RF frequency ranges and service types include ultra-high frequency (UHF), super high frequency (SHF), extremely high frequency (EHF), or other parameters defined by different organizations.
(31) The functional block diagrams, operational scenarios and sequences, and flow diagrams provided in the Figures are representative of exemplary systems, environments, and methodologies for performing novel aspects of the disclosure. While, for purposes of simplicity of explanation, methods included herein may be in the form of a functional diagram, operational scenario or sequence, or flow diagram, and may be described as a series of acts, it is to be understood and appreciated that the methods are not limited by the order of acts, as some acts may, in accordance therewith, occur in a different order and/or concurrently with other acts from that shown and described herein. For example, those skilled in the art will understand and appreciate that a method could alternatively be represented as a series of interrelated states or events, such as in a state diagram. Moreover, not all acts illustrated in a methodology may be required for a novel implementation.
(32) The various materials and manufacturing processes discussed herein are employed according to the descriptions above. However, it should be understood that the disclosures and enhancements herein are not limited to these materials and manufacturing processes, and can be applicable across a range of suitable materials and manufacturing processes. Thus, the descriptions and figures included herein depict specific implementations to teach those skilled in the art how to make and use the best options. For the purpose of teaching inventive principles, some conventional aspects have been simplified or omitted. Those skilled in the art will appreciate variations from these implementations that fall within the scope of this disclosure. Those skilled in the art will also appreciate that the features described above can be combined in various ways to form multiple implementations.