Waveguide antenna fabrication
First Claim
1. A method of manufacturing a waveguide antenna comprising:
- providing a first metal layer including one or more waveguide channels formed into the first metal layer, wherein the first metal layer is a sheet of metal having a predefined thickness;
selecting, on the first metal layer, at least one coupling surface proximate to at least edges of the one or more waveguide channels;
removing an oxidation layer from a second metal layer and from a third metal layer;
providing a reactive metal foil between a first surface of the first metal layer and a surface of the second metal layer, and between a second surface of the first metal layer and a surface of the third metal layer, the second surface of the first metal layer being opposite the first surface, wherein the reactive metal foil is provided to the selected at least one coupling surface;
providing a fusible metal material between the first surface of the first metal layer and the surface of the second metal layer, and between the second surface of the first metal layer and the surface of the third metal layer, wherein the fusible metal material is provided to the selected at least one coupling surface; and
coupling the first surface of the first metal layer to the surface of the second metal layer and coupling the second surface of the first metal layer to the surface of the third metal layer, wherein the couplings comprise;
igniting the reactive metal foil so as to locally provide heat to the surfaces of the first, second, and third metal layers and melt the fusible metal material, andcooling the melted fusible metal material.
6 Assignments
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Accused Products
Abstract
An example method of fabricating a waveguide antenna may involve providing a first metal layer with waveguide channels formed therein. The method may also involve selecting at least one coupling surface on the first metal layer that is proximate to at least edges of the waveguide channels. The method may also involve removing respective oxidation layers from second and third metal layers. The method may also involve providing, to the selected at least one coupling surface, a fusible metal material and a reactive metal foil between surfaces of the first and second metal layers and between surfaces of the first and third metal layers. The method may also involve coupling the layers together by igniting the reactive metal foil so as to locally provide heat to the surfaces of the layers and melt the fusible metal material, and then cooling the melted fusible metal material.
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Citations
22 Claims
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1. A method of manufacturing a waveguide antenna comprising:
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providing a first metal layer including one or more waveguide channels formed into the first metal layer, wherein the first metal layer is a sheet of metal having a predefined thickness; selecting, on the first metal layer, at least one coupling surface proximate to at least edges of the one or more waveguide channels; removing an oxidation layer from a second metal layer and from a third metal layer; providing a reactive metal foil between a first surface of the first metal layer and a surface of the second metal layer, and between a second surface of the first metal layer and a surface of the third metal layer, the second surface of the first metal layer being opposite the first surface, wherein the reactive metal foil is provided to the selected at least one coupling surface; providing a fusible metal material between the first surface of the first metal layer and the surface of the second metal layer, and between the second surface of the first metal layer and the surface of the third metal layer, wherein the fusible metal material is provided to the selected at least one coupling surface; and coupling the first surface of the first metal layer to the surface of the second metal layer and coupling the second surface of the first metal layer to the surface of the third metal layer, wherein the couplings comprise; igniting the reactive metal foil so as to locally provide heat to the surfaces of the first, second, and third metal layers and melt the fusible metal material, and cooling the melted fusible metal material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 21)
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11. A waveguide antenna comprising:
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a first metal layer including (i) one or more waveguide channels formed into the first metal layer and (ii) at least one coupling surface proximate to at least edges of the one or more waveguide channels, wherein the first metal layer is a sheet of metal having a predefined thickness; a second metal layer and a third metal layer, each with respective oxidation layers removed; a reactive metal foil that is (i) provided to the at least one coupling surface, (ii) located between a first surface of the first metal layer and a surface of the second metal layer, and (iii) located between a second surface of the first metal layer and a surface of the third metal layer, the second surface of the first metal layer being opposite the first surface; a fusible metal material that is (i) provided to the at least one coupling surface, (ii) located between the first surface of the first metal layer and the surface of the second metal layer, and (iii) located between the second surface of the first metal layer and the surface of the third metal layer; and wherein the first surface of the first metal layer is coupled to the surface of the second metal layer and the second surface of the first metal layer is coupled to the surface of the third metal layer by; igniting the reactive metal foil so as to locally provide heat to the surfaces of the first, second, and third metal layers and melt the fusible metal material, and cooling the melted fusible metal material. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19, 20, 22)
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Specification