Patent Publication Number: US-10790591-B2

Title: Integrated device and manufacturing method thereof

Description:
RELATED APPLICATIONS 
     This application claims priority from European Patent Application No. EP18182598.5 (filed 2018 Jul. 10), the entirety of which is incorporated by reference herein. 
     TECHNICAL FIELD 
     The invention relates to an integrated device, especially comprising a horn antenna, a waveguide transition element, and an orthomode transducer, and a corresponding manufacturing method thereof. 
     BACKGROUND 
     Generally, in times of an increasing number of applications providing wireless communication capabilities, there is a growing need of a cost-efficient integrated device and a corresponding manufacturing method thereof for efficiently transmitting and/or receiving signals with respect to said applications in order to verify a proper functioning thereof. 
     The publication KR1020150069792A discloses a jig device for measuring the performance of a polarizer and, more specifically, a jig capable of measuring the performance of a polarizer changing a phase. Furthermore, the jig measures the performance of a polarizer outputting polarization, inputted through an input terminal of the polarizer, through an output terminal of the polarizer by changing the polarization into circular polarization. The jig includes an input terminal measuring jig receiving linear polarization having an inclined angle to spread the polarization to the input terminal of the polarizer, and an output terminal measuring jig separating the circular polarization, delivered from the output terminal, into horizontal polarization and vertical polarization to output the polarization to different output ports. However, due to the fact that said jig consists of many separate parts, its manufacturing is complex and expensive. 
     Accordingly, there is a need to provide a cost-efficient integrated device and a corresponding manufacturing method thereof. 
     SOME EXAMPLE EMBODIMENTS 
     Embodiments of the present invention advantageously address the foregoing requirements and needs, as well as others, by providing a cost-efficient integrated device and a corresponding manufacturing method thereof. 
     According to a first aspect of the invention, an integrated device is provided. The integrated device comprises a horn antenna with an antenna waveguide feed, a waveguide transition element comprising a first end connected to the antenna waveguide feed and a second end, and an orthomode transducer comprising a common waveguide connected to the second end of the waveguide transition element and at least two separate waveguides. In this context, the orthomode transducer is adapted to couple at least two orthogonal linear polarized fields into the common waveguide of the orthomode transducer with the aid of the at least two separate waveguides of the orthomode transducer and/or vice versa. 
     In addition to this, the horn antenna is preferably adapted to support at least two waveguide modes corresponding to the at least two orthogonal linear polarized fields. Furthermore, the integrated device is preferably manufactured in at least two separate blocks such that each part of the at least two piece assembly is constructed as external protrusions and/or holes and/or partial holes. Advantageously, in this manner, a reduced complexity and a high cost-efficiency can be ensured. 
     According to a further preferred implementation form of the first aspect of the invention, the antenna waveguide feed is an elliptical antenna waveguide feed, preferably a circular antenna waveguide feed. Advantageously, for instance, complexity can further be reduced. 
     According to a further preferred implementation form of the first aspect of the invention, the first end of the waveguide transition element is of elliptical shape, preferably of circular shape. Advantageously, for example, complexity can further be reduced. 
     According to a further preferred implementation form of the first aspect of the invention, the second end of the waveguide transition element is of rectangular shape, preferably of square shape. Advantageously, for instance, complexity can further be reduced, thereby especially increasing cost-efficiency. 
     According to a further preferred implementation form of the first aspect of the invention, the common waveguide of the orthomode transducer is of rectangular shape, preferably of square shape. Advantageously, for example, cost-efficiency can further be increased especially by reducing complexity. 
     According to a further preferred implementation form of the first aspect of the invention, at least one of the at least two separate waveguides of the orthomode transducer is of rectangular shape. Advantageously, for instance, a further reduced complexity can be ensured. According to a further preferred implementation form of the first aspect of the invention, alignment pins and threaded holes are provided on the at least two piece assembly to facilitate the assembly. Advantageously, in this manner, an accurate and efficient assembly can be guaranteed. 
     According to a further preferred implementation form of the first aspect of the invention, the integrated device further comprises at least one waveguide to coax interface, preferably at least one rectangular waveguide to coax interface. In this context, the at least one waveguide to coax interface, preferably the at least one rectangular waveguide to coax interface, is connected to at least one of the at least two separate waveguides of the orthomode transducer. Advantageously, a coaxial transmission line or a coaxial cable can efficiently be connected. 
     According to a further preferred implementation form of the first aspect of the invention, the at least one waveguide to coax interface, preferably the at least one rectangular waveguide to coax interface, is constructed as a separate and/or detachable part. Advantageously, for instance, complexity can further be reduced. 
     According to a further preferred implementation form of the first aspect of the invention, the integrated device comprises at least one screw connection for connecting the at least two separate blocks. Advantageously, assembling can be performed in a cost-efficient manner. 
     According to a further preferred implementation form of the first aspect of the invention, at least one of the at least two separate blocks comprises metal, preferably metal comprising a gold plating, more preferably aluminum, most preferably aluminum comprising a gold plating, and/or graphene, preferably a graphene plating. Advantageously, waveguide modes can be guided with a high quality. 
     According to a further preferred implementation form of the first aspect of the invention, the integrated device is manufactured in three separate blocks such that each part of the three piece assembly is constructed as external protrusions and/or partial holes. In this context, the external protrusions and/or partial holes are milled without forming enclosed internal cavities and/or holes. Advantageously, especially due to an easy milling process, cost-efficiency can further be increased. 
     According to a second aspect of the invention, a manufacturing method for manufacturing an integrated device comprising a horn antenna, a waveguide transition element, and an orthomode transducer is provided. The manufacturing method comprises the steps of manufacturing the integrated device in at least two separate blocks, and constructing each part of the at least two piece assembly as external protrusions and/or holes and/or partial holes. Advantageously, in this manner, a reduced complexity and a high cost-efficiency can be ensured. 
     According to a first preferred implementation form of the second aspect of the invention, the manufacturing method further comprises the step of providing alignment pins and threaded holes on the at least two piece assembly to facilitate the assembly. Advantageously, in this manner, an accurate and efficient assembly can be guaranteed. 
     According to a further preferred implementation form of the second aspect of the invention, the manufacturing method further comprises the steps of manufacturing the integrated device in three separate blocks, constructing each part of the three piece assembly as external protrusions and/or partial holes, and milling the external protrusions and/or partial holes without forming enclosed internal cavities and/or holes. Advantageously, especially due to an easy milling process, cost-efficiency can further be increased. 
     Still other aspects, features, and advantages of the present invention are readily apparent from the following detailed description, simply by illustrating a number of particular embodiments and implementations, including the best mode contemplated for carrying out the present invention. The present invention is also capable of other and different embodiments, and its several details can be modified in various obvious respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawing and description are to be regarded as illustrative in nature, and not as restrictive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Exemplary embodiments of the invention are now further explained with respect to the drawings by way of example only, and not for limitation. In the drawings: 
         FIG. 1  shows a first exemplary embodiment of the first aspect of the invention based on a three piece assembly; 
         FIG. 2  shows the bottom part of the first exemplary embodiment; 
         FIG. 3  shows the first top part of the first exemplary embodiment; 
         FIG. 4  shows the second top part of the first exemplary embodiment; 
         FIG. 5  shows a second exemplary embodiment of the inventive integrated device based on a two piece assembly; 
         FIG. 6  shows the bottom part of the second exemplary embodiment; 
         FIG. 7  shows the top part of the second exemplary embodiment; and 
         FIG. 8  shows a flow chart of an exemplary embodiment of the second aspect of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     A cost-efficient integrated device and a corresponding manufacturing method thereof, are described. In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the invention. It is apparent, however, that the invention may be practiced without these specific details or with an equivalent arrangement. In other instances, well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring the invention. 
     Firstly,  FIG. 1  illustrates a first exemplary embodiment of an inventive integrated device  10 . The integrated device  10  comprises a horn antenna  31  with an antenna waveguide feed  32 , a waveguide transition element  33  comprising a first end connected to the antenna waveguide feed and a second end, and an orthomode transducer comprising a common waveguide  34  connected to the second end of the waveguide transition element and two separate waveguides, especially a first separate waveguide  35  and a second separate waveguide  36 . 
     In this context, the orthomode transducer is adapted to couple at least two orthogonal linear polarized fields into the common waveguide  34  of the orthomode transducer with the aid of the two separate waveguides  35 ,  36  of the orthomode transducer and/or vice versa, wherein the horn antenna  31  is adapted to support at least two waveguide modes corresponding to the at least two orthogonal linear polarized fields. 
     As it can further be seen from  FIG. 1 , the integrated device or integrated part  10  is manufactured in three separate blocks  11 ,  12 ,  13  such that each part of the three piece assembly is constructed as external protrusions and/or partial holes, wherein the external protrusions and/or partial holes are especially milled without forming enclosed internal cavities and/or holes. 
     Furthermore, it is noted that the antenna waveguide feed  32  is a circular antenna waveguide feed, whereas the common waveguide  34  of the orthomode transducer is of square shape. 
     As a consequence of this, the first end of the waveguide transition element  33  is of circular shape, whereas the second end of the waveguide transition element  33  is of square shape. In other words, in this exemplary case, the wave guide transition element  33  is a circular to square waveguide transition element. 
     Moreover, according to  FIG. 1 , each of the two separate waveguides  35 ,  36  of the orthomode transducer is of rectangular shape. 
     It is noted that it might be particularly advantageous if alignment pins and threaded holes are provided on the three piece assembly  10  in order to facilitate the assembly. 
     Whereas said alignment pins and threaded holes are not explicitly shown in  FIG. 1 ,  FIG. 1  depicts that the integrated device  10  further comprises two waveguide to coax interfaces, preferably two rectangular waveguide to coax interfaces, especially a first rectangular waveguide to coax interface  37  and a second rectangular waveguide to coax interface  38 . 
     In this context, each of the two rectangular waveguide to coax interfaces  37 ,  38  is connected to the respective one of the two separate waveguides  35 ,  36  of the orthomode transducer. 
     Preferably, each of the two rectangular waveguide to coax interfaces  37 ,  38  may be constructed as a separate and/or detachable part. 
     Furthermore, it is noted that the integrated device or part  10  may preferably comprise at least one screw connection for connecting the three separate blocks  11 ,  12 ,  13 . 
     It is further noted that at least one of the three separate blocks  11 ,  12 ,  13  may especially comprise metal, preferably metal comprising a gold plating, more preferably aluminum, most preferably aluminum comprising a gold plating, and/or graphene, preferably a graphene plating. 
     Moreover,  FIG. 2  illustrates the bottom part  11  of the first exemplary embodiment according to  FIG. 1 . As it can be seen, before the waves guided by the first separate waveguide  35  and the second separate waveguide  36  enter the common waveguide  34  of the orthomode transducer, the second separate waveguide  36  is divided into two partial waveguides, especially a first partial waveguide  361  and a second partial waveguide  362 . 
     In this context, it is noted that the respective pathways of the first partial waveguide  361  and the second partial waveguide  362  are symmetric with respect to an axis, especially a longitudinal axis, of the second separate waveguide  36 . It might be particularly advantageous if said axis, especially said longitudinal axis, runs through the center of the second separate waveguide  36 . 
     Furthermore, it might be particularly advantageous if at least one, exemplarily each, of the partial waveguides  361 ,  362  is of a curved shape, a parabolic shape, or an U-shape. 
     With special respect to the orthomode transducer comprising the common waveguide  34 , the first separate waveguide  35 , and the second separate waveguide  36 , it is noted that the common waveguide  34  and the second separate waveguide  36  are especially comprised, preferably intersected or touched, by the same plane. In addition to this, the first separate waveguide  35  is preferably perpendicularly arranged with respect to the common waveguide  34  and/or the second separate waveguide  36 . 
     Moreover, in accordance with  FIG. 2 , the region  39 , especially being located near the common waveguide  34  and in which the first separate waveguide  35  is arranged, is beveled. Preferably, the respective surface rises with decreasing distance from the common waveguide  34  or from the horn antenna  31 , respectively. In addition to this or as an alternative, especially within the common waveguide  34  or within an entry area of the common waveguide  34 , the respective surface falls with decreasing distance from the horn antenna  31 . 
     Furthermore, with respect to the bottom part  11  illustrated by  FIG. 2 , it is noted that said exemplary bottom part  11  comprises a part of the horn antenna  31 , a part of the antenna waveguide feed  32 , a part of the waveguide transition element  33 , a part of the common waveguide  34 , a part of the first partial waveguide  361 , a part of the second partial waveguide  362 , a part of the second separate waveguide  36 , and a part of the second rectangular waveguide to coax interface  38 . 
     In addition to this, as shown in  FIG. 3 , the first top part  12  of the first embodiment  10  comprises a part of the horn antenna  31 , a part of the antenna waveguide feed  32 , a part of the waveguide transition element  33 , a part of the common waveguide  34 , a part of the first partial waveguide  361 , a part of the second partial waveguide  362 , and a part of the first separate waveguide  35 . 
     Further additionally, in accordance with  FIG. 4 , the second top part  13  of the first embodiment  10  comprises a part of the first partial waveguide  361 , a part of the second partial waveguide  362 , a part of the first separate waveguide  35 , a part of the second separate waveguide  36 , the first rectangular waveguide to coax interface  37 , and a part of the second rectangular waveguide to coax interface  38 . 
     Now, with respect to  FIG. 5 , a second exemplary embodiment of an inventive integrated device  20  is depicted. The integrated device  20  comprises a horn antenna  41  with an antenna waveguide feed  42 , a waveguide transition element  43  comprising a first end connected to the antenna waveguide feed  42  and a second end, and an orthomode transducer comprising a common waveguide  44  connected to the second end of the waveguide transition element  43  and two separate waveguides, especially a first separate waveguide  45  and a second separate waveguide  46 . 
     In this context, the orthomode transducer is adapted to couple at least two orthogonal linear polarized fields into the common waveguide  44  of the orthomode transducer with the aid of the two separate waveguides  45 ,  46  of the orthomode transducer and/or vice versa, wherein the horn antenna  41  is adapted to support at least two waveguide modes corresponding to the at least two orthogonal linear polarized fields. 
     As it can further be seen from  FIG. 5 , the integrated device  20  is manufactured in two separate blocks  21 ,  22  such that each part of the two piece assembly is constructed as external protrusions and/or and/or holes and/or partial holes. 
     Furthermore, it is noted that the antenna waveguide feed  42  is a circular antenna waveguide feed, whereas the common waveguide  44  of the orthomode transducer is of square shape. 
     As a consequence of this, the first end of the waveguide transition element  43  is of circular shape, whereas the second end of the waveguide transition element  43  is of square shape. In other words, in this exemplary case, the wave guide transition element  43  is a circular to square waveguide transition element. 
     Moreover, according to  FIG. 5 , each of the two separate waveguides  35 ,  36  of the orthomode transducer is of rectangular shape. 
     It is noted that it might be particularly advantageous if alignment pins and threaded holes are provided on the two piece assembly  20  in order to facilitate the assembly. 
     Whereas said alignment pins and threaded holes are not explicitly shown in  FIG. 5 ,  FIG. 5  illustrates that the integrated device  20  further comprises two waveguide to coax interfaces, preferably two rectangular waveguide to coax interfaces, especially a first rectangular waveguide to coax interface  47  and a second rectangular waveguide to coax interface  48 . 
     In this context, each of the two rectangular waveguide to coax interfaces  47 ,  48  is connected to the respective one of the two separate waveguides  45 ,  46  of the orthomode transducer. 
     Preferably, each of the two rectangular waveguide to coax interfaces  47 ,  48  may be constructed as a separate and/or detachable part. 
     Furthermore, it is noted that the integrated device  20  may preferably comprise at least one screw connection for connecting the two separate blocks  21 ,  22 . 
     It is further noted that at least one of the two separate blocks  21 ,  22  may especially comprise metal, preferably metal comprising a gold plating, more preferably aluminum, most preferably aluminum comprising a gold plating, and/or graphene, preferably a graphene plating. 
     Moreover,  FIG. 6  illustrates the bottom part  21  of the second exemplary embodiment according to  FIG. 5 . As it can be seen, before the waves guided by the first separate waveguide  45  and the second separate waveguide  46  enter the common waveguide  44  of the orthomode transducer, the second separate waveguide  46  is divided into two partial waveguides, especially a first partial waveguide  461  and a second partial waveguide  462 . 
     In this context, it is noted that the respective pathways of the first partial waveguide  461  and the second partial waveguide  462  are symmetric with respect to an axis, especially a longitudinal axis, of the second separate waveguide  46 . It might be particularly advantageous if said axis, especially said longitudinal axis, runs through the center of the second separate waveguide  46 . 
     Furthermore, it might be particularly advantageous if at least one, exemplarily each, of the partial waveguides  461 ,  462  is of a curved shape, a parabolic shape, or an U-shape. 
     With special respect to the orthomode transducer comprising the common waveguide  44 , the first separate waveguide  45 , and the second separate waveguide  46 , it is noted that the common waveguide  44  and the second separate waveguide  46  are especially comprised, preferably intersected or touched, by the same plane. In addition to this, the first separate waveguide  45  is preferably perpendicularly arranged with respect to the common waveguide  44  and/or the second separate waveguide  46 . 
     Moreover, in accordance with  FIG. 6 , the region  49 , especially being located near the common waveguide  44  and in which the first separate waveguide  45  is arranged, is beveled. Preferably, the respective surface rises with decreasing distance from the common waveguide  44  or from the horn antenna  41 , respectively. In addition to this or as an alternative, especially within the common waveguide  44  or within an entry area of the common waveguide  44 , the respective surface falls with decreasing distance from the horn antenna  41 . 
     Furthermore, with respect to the bottom part  21  illustrated by  FIG. 6 , it is noted that said exemplary bottom part  21  comprises a part of the horn antenna  41 , a part of the antenna waveguide feed  42 , a part of the waveguide transition element  43 , a part of the common waveguide  44 , a part of the first partial waveguide  461 , a part of the second partial waveguide  462 , a part of the second separate waveguide  46 , and a part of the second rectangular waveguide to coax interface  48 . 
     In addition to this, as illustrated by  FIG. 7 , the top part  22  of the second embodiment  20  comprises a part of the horn antenna  41 , a part of the antenna waveguide feed  42 , a part of the waveguide transition element  43 , a part of the common waveguide  44 , the first separate waveguide  45 , a part of the first partial waveguide  461 , a part of the second partial waveguide  462 , a part of the second separate waveguide  46 , the first rectangular waveguide to coax interface  47 , and a part of the second rectangular waveguide to coax interface  48 . 
     In this context, it is noted that it might be particularly advantageous if said part is especially a half. 
     Finally,  FIG. 8  shows a flow chart of an exemplary embodiment of the inventive manufacturing method. In a first step  100 , an integrated device comprising a horn antenna, a waveguide transition element, and an orthomode transducer is manufactured in at least two separate blocks. Then, in a second step  101 , each part of the at least two piece assembly is constructed as external protrusions and/or holes and/or partial holes. 
     In this context, it might be particularly advantageous if the antenna waveguide feed is manufactured as an elliptical antenna waveguide feed, preferably a circular antenna waveguide feed. 
     Further advantageously, the first end of the waveguide transition element may especially be of elliptical shape, preferably of circular shape. 
     In addition to this or as an alternative, the second end of the waveguide transition element may especially be of rectangular shape, preferably of square shape. 
     Further additionally or alternatively, the common waveguide of the orthomode transducer may especially be of rectangular shape, preferably of square shape. 
     Furthermore, it is noted that at least one of the at least two separate waveguides of the orthomode transducer may preferably be of rectangular shape. 
     Moreover, it might be particularly advantageous if the manufacturing method further comprises the step of providing alignment pins and threaded holes on the at least two piece assembly to facilitate the assembly. 
     In addition to this or as an alternative, the manufacturing method may further comprise the steps of providing at least one waveguide to coax interface, preferably at least one rectangular waveguide to coax interface, for the integrated device, and connecting the at least one waveguide to coax interface, preferably the at least one rectangular waveguide to coax interface, to at least one of the at least two separate waveguides of the orthomode transducer. 
     In this context, the manufacturing method may further comprise the step of constructing the at least one waveguide to coax interface, preferably the at least one rectangular waveguide to coax interface, as a separate and/or detachable part. 
     Additionally or alternatively, the manufacturing method may further comprise the step of connecting the at least two separate blocks of the integrated device with the aid of at least one screw connection. 
     In further addition to this or as a further alternative, at least one of the at least two separate blocks may especially comprise metal, preferably metal comprising a gold plating, more preferably aluminum, most preferably aluminum comprising a gold plating, and/or graphene, preferably a graphene plating. 
     Furthermore, it is noted that it might be particularly advantageous if the manufacturing method comprises the steps of manufacturing the integrated device in three separate blocks, constructing each part of the three piece assembly as external protrusions and/or partial holes, and milling the external protrusions and/or partial holes without forming enclosed internal cavities and/or holes. 
     While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Numerous changes to the disclosed embodiments can be made in accordance with the disclosure herein without departing from the spirit or scope of the invention. For example, a current may be measured instead of a voltage. Thus, the breadth and scope of the present invention should not be limited by any of the above-described embodiments. Rather, the scope of the invention should be defined in accordance with the following claims and their equivalents. 
     Although the invention has been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application.