This nonprovisional patent application is related to U.S. patent application Ser. No. 16/248,285 filed on Jan. 15, 2019, titled “BUILD ORIENTATION FOR ADDITIVE MANUFACTURING OF COMPLEX STRUCTURES”. This nonprovisional patent application is also related to U.S. Provisional Patent Application No. 62/767,481, filed on Nov. 14, 2018, titled: “HOLLOW METAL WAVEGUIDES HAVING IRREGULAR HEXAGONAL CROSS-SECTIONS AND METHODS OF FABRICATING SAME”. The contents of all three patent applications recited above are hereby incorporated by reference as if fully set forth herein for all purposes.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates generally to mechanically-rotated waveguide switches for electromagnetic energy propagation. More particularly, this invention relates to a waveguide switch rotor with improved isolation.

Description of Related Art

Mechanical waveguide switches are used in ground, air, and space antenna and radio frequency (RF) systems for switching an electromagnetic signal from one routing to a different routing. These mechanical waveguide switches can include multiple configurations of 1-1 (single-pole single-throw, SPST), 1-2 (single-pole dual-throw), 2-2 (dual-pole dual-throw, DPDT), and other routings of one or more inputs to one or more outputs. Current mechanical switches contain a rotor (central rotating unit) and stator (outer fixed body). The rotor and stator have waveguide channels that allow for routing of inputs to outputs for the various states, and the rotor rotates axially to achieve the different states. Current methods for designing the rotor require small gaps between rotor and stator to achieve high isolation from inputs to unconnected outputs (isolation). As of this writing, fabrication of such mechanical waveguide switches is challenging due to tight tolerance requirements on the rotor and stator that are imposed by the small gap between the rotor and stator.

However, a need still exists in the art for a waveguide switch rotor with improved isolation and ease of fabrication.

BRIEF SUMMARY OF THE INVENTION

An embodiment of a waveguide switch rotor is disclosed. The embodiment of a waveguide switch rotor may include a cylindrical rotor face extending between a rotor top and a rotor bottom with an axis of rotation passing through the rotor top and the rotor bottom, a first pair of waveguide ports disposed onto the cylindrical rotor face defining a first waveguide path passing into and out of the rotor face and a lattice of evenly-spaced isolation posts extending from the cylindrical rotor face and surrounding the pair of waveguide ports.

An embodiment of a waveguide switch housing is disclosed. The embodiment of a waveguide switch housing may include a waveguide switch rotor. The embodiment of a waveguide switch rotor may include a cylindrical rotor face extending between a rotor top and a rotor bottom, with an axis of rotation passing through the rotor top and the rotor bottom. The embodiment of a waveguide switch rotor may further include a first pair of rotor waveguide ports disposed onto the cylindrical rotor face defining a first waveguide path passing into and out of the rotor face. The embodiment of a waveguide switch rotor may further include a lattice of evenly-spaced isolation posts extending from the cylindrical rotor face and surrounding the pair of rotor waveguide ports. Finally, the embodiment of a waveguide switch housing may further include a waveguide switch stator having a cylindrical opening for receiving the waveguide switch rotor. The embodiment of a waveguide switch stator may include a first pair of stator waveguide ports corresponding to the first pair of rotor waveguide ports when the waveguide switch rotor is in a first rotational position. The embodiment of a waveguide switch stator may further include a second pair of stator waveguide ports corresponding to the first pair of rotor waveguide ports when the waveguide switch rotor is in a second rotational position.

An embodiment of a meander clamping mechanism formed into a base member for rotationally attaching a rotational member to the base member such that the rotational member is configured to rotate about an axis of rotation relative to the meander clamping mechanism formed into the base member is disclosed. The embodiment of a meander clamping mechanism may include a hollow cylindrical member having a cylindrical inner wall and a cylindrical outer wall, both of the walls extending coaxially with the axis of rotation. The embodiment of a meander clamping mechanism may further include the inner wall defining a rotational member receptacle configured to receive the rotational member. The embodiment of a meander clamping mechanism may further include the inner wall further including radial and longitudinal inner slots extending toward the outer wall. The embodiment of a meander clamping mechanism may further include the outer wall further including radial and longitudinal outer slots extending toward the inner wall. The embodiment of a meander clamping mechanism may further include the inner and outer slots being interdigitated. Finally, the embodiment of a meander clamping mechanism may further include wherein a clamping ring having a final inside diameter slightly less than an outside diameter of the outer wall, pressed axially around the outer wall and configured to flex the mechanism radially inward to grasp the rotational member disposed inside the rotational member receptacle.

Additional features and advantages of the invention will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example, features of embodiments of the present invention.

