U.S. patent number 3,925,883 [Application Number 05/453,742] was granted by the patent office on 1975-12-16 for method for making waveguide components.
This patent grant is currently assigned to Varian Associates. Invention is credited to Charles T. Cavalear.
United States Patent |
3,925,883 |
Cavalear |
December 16, 1975 |
Method for making waveguide components
Abstract
Metallic sheet stock is stamped in accordance with certain
predetermined patterns to derive members, some of which are bent to
predetermined shapes, to define waveguide components which are
utilized as components of microwave devices such as TR tubes. The
stamped metal members are, in the case of cold rolled steel, copper
plated and brazed together in a suitable jig structure to form the
final composite microwave component, such as a TR tube. Waveguide
flanges, iris structures, and waveguides are constructed in this
manner.
Inventors: |
Cavalear; Charles T. (Hamilton,
MA) |
Assignee: |
Varian Associates (Palo Alto,
CA)
|
Family
ID: |
23801882 |
Appl.
No.: |
05/453,742 |
Filed: |
March 22, 1974 |
Current U.S.
Class: |
29/600;
228/173.6; 228/170 |
Current CPC
Class: |
H01P
11/00 (20130101); Y10T 29/49016 (20150115) |
Current International
Class: |
H01P
11/00 (20060101); H01P 011/00 (); B23K
031/02 () |
Field of
Search: |
;29/600,472.3,477.7
;333/13,95R,98 ;113/12E,12HA,12UE,116CC |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Smith; Al Lawrence
Assistant Examiner: Godici; Nicholas P.
Attorney, Agent or Firm: Cole; Stanley Z. Pressman; David R.
Nelson; Richard B.
Claims
What is claimed is:
1. A method for making a microwave waveguide apparatus comprising
the following steps:
bending a first metallic sheet into an open-sided rectangular
channel member,
forming a second metallic sheet to provide a waveguide obstacle
having outline dimensions fitting the inner transverse dimensions
of said channel, said obstacle including an opening to define a
waveguide iris, said forming of said second sheet including the
step of bending at least one side of said sheet to form an angular
foot projecting from said side,
positioning said obstacle within and transverse to said channel
with said foot abutting a surface of said channel,
covering the open side of said channel with a third metallic sheet,
and
sealing said channel, said obstacle and said third sheet together
to form a tubular waveguide with said obstacle closing said
waveguide except for said iris in said obstacle.
2. The method of claim 1 wherein the step of forming said second
sheet includes bending two parallel angular feet on opposite sides
of said second sheet and the step of covering said open side of
said channel includes abutting said third sheet to one of said
angular feet.
3. The method of claim 1 wherein said opening in said second sheet
is shaped to include a reentrant projection.
4. The method of claim 1 wherein the line of said bending crosses
said opening, whereby a cut-out is formed in said foot.
5. The method of claim 4 further including the step of forming an
aperture in one of said first and said third sheets and wherein the
step of positioning said obstacle includes aligning said cut-out
with said aperture.
6. The method of claim 5 further including the step of positioning
a metallic cone-shaped waveguide obstacle within said aperture with
the tip of said cone-shaped obstacle projecting into said iris.
7. In a method for making a microwave waveguide apparatus, the
steps of:
bending a first metallic sheet into a first open-sided channel
member,
forming in a second metallic sheet at least one opening to define
two waveguide irises,
bending said second sheet into a second channel having aligned
openings in both sidewalls, said second channel being dimensioned
to fit within said first channel,
positioning said second channel within and transverse to said first
channel,
covering the open side of said first channel with a third metallic
sheet, and
sealing said first and second channels and said third sheet
together to form a tubular waveguide with two axially spaced
transverse obstacles, each containing an iris.
8. The method of claim 7 wherein the step of bending said second
sheet includes bending the ends of the sidewalls of said second
channel to form angular feet positioned in a surface parallel to
the bottom wall of said second channel and wherein the step of
positioning said second channel includes abutting one of the
parallel surfaces of said feet to said bottom wall of said first
channel.
Description
BACKGROUND OF THE INVENTION
The present invention relates in general to an improved method for
making microwave waveguide components, such as TR tubes, from parts
stamped from metallic sheet stock material, whereby the
manufacturing costs are substantially reduced.
DESCRIPTION OF THE PRIOR ART
Heretofore, microwave TR tubes, utilized as receiver protectors in
radars, have been constructed by the use of extruded waveguide
either of steel, copper or aluminum. The extruded waveguide
sections have been slotted and drilled to receive certain waveguide
obstacles, such as cones and inductive irises of the conventional
TR tubes. The waveguide obstacles were mounted within the slotted
or drilled portions of the extruded waveguide sections and
assembled with waveguide flanges which were often made by stamping
of rectangular blanks from sheet stock followed by milling and
drilling operations. In some cases, the waveguide flange blank was
drawn to provide an axially directed lip at the inner rectangular
opening in the flange which was to receive the waveguide or other
components to which the flange was to be affixed.
After the TR tube components were assembled they were brazed
together to form an integral assembly which was then evacuated and
filled with a suitable ionizable gas.
Examples of prior art TR tubes are found in the following U.S. Pat.
Nos.: 2,710,932 issued June 14, 1955 and 2,734,171 issued Feb. 7,
1956.
The problem with the prior art method of fabricating TR tubes was
that a substantial amount of machining was required on the various
components. In addition, the extruded waveguide was relatively
expensive, especially in small quantity.
Accordingly, it is desirable to provide an improved method for
making TR tubes and the microwave components thereof which
eliminates much of the machining heretofore performed on the
various components.
SUMMARY OF THE PRESENT INVENTION
The principal object of the present invention is the provision of
an improved method for making TR tubes and components thereof.
In one feature of the present invention, a section of rectangular
waveguide is formed by stamping a rectangular blank of metal from
sheet stock and then bending the metal stamping into a channel
having an open side. A second stamping from metallic sheet stock is
employed as a cover for covering the open side of the channel to
define the rectangular waveguide. The cover is sealed to the
channel member by brazing, welding or the like.
In another feature of the present invention, waveguide iris is
formed by stamping a member from metallic sheet stock. The stamped
member is perforated with a certain pattern such that when the
stamping is bent, a waveguide iris obstacle is obtained which is
dimensioned to be received within a section of rectangular
waveguide.
In another feature of the present invention, an internally flared
waveguide flange assembly is formed by stacking a plurality of
rectangular rings at the lip of a rectangular opening in a stamped
plate. The stacked rings are brazed together and to the plate to
form a composite flange assembly having an internally flared
lip.
In another feature of the present invention, the waveguide body of
a TR tube is formed by stamping from sheet stock a first member
having a pattern of perforations therein to receive waveguide
obstacles to be disposed within the body of the TR tube. The
stamped member is then bent into an open sided channel, the
waveguide obstacles are inserted into the perforations and a
stamped cover member is positioned over the open sided channel
containing the waveguide obstacles. The assembly is then sealed
together to form the body of a TR tube.
In another feature of the present invention, a dual waveguide
flange having internal shoulders around two rectangular openings in
the flange is formed by brazing together a plurality of metallic
stampings from sheet stock one of the stampings having dual
rectangular apertures in side-by-side relation of smaller inside
dimensions than the rectangular opening in the adjacent metallic
stamping, whereby upon brazing the two members together the
internal shoulder is formed in the composite dual waveguide flange
assembly.
Other features and advantages of the present invention will become
apparent upon a perusal of the following specification taken in
connection with the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of a pair of stampings to be
utilized in the fabrication of a section of rectangular
waveguide,
FIG. 2 is a view similar to that of FIG. 1 showing the bottom
metallic stamping being bent to form a channel structure,
FIG. 3 is a perspective view of the rectangular waveguide
fabricated according to the method of FIGS. 1 and 2,
FIG. 4 is a view similar to that of FIG. 1 depicting the pattern of
apertures stamped into the members when the members are to form the
body of a TR tube,
FIG. 5 is a perspective view of a metallic stamping forming the
first step in the fabrication of a dual tandem TR tube according to
the method of the present invention,
FIG. 6 is a perspective view of the shape into which the plate of
FIG. 5 is bent to form the tandem iris obstacles,
FIG. 7 is a perspective view of the assembly of the waveguide
obstacle of FIG. 6 in the channel shaped portion of the body formed
by bending the bottom stamping of FIG. 4,
FIG. 8 is a view similar to that of FIG. 7 depicting the step of
closing the open side of the channel body member and insertion of
the cone obstacles within the irises of the body,
FIG. 9 is a perspective view similar to that of FIG. 8 showing the
structure of FIG. 8 with waveguide flanges affixed to opposite ends
thereof,
FIG. 10 is a view similar to that of FIG. 5 depicting an
alternative iris type stamping,
FIG. 11 is a view similar to that of FIG. 6 depicting the method of
bending the plates of FIG. 10 and showing the relation of the
resultant iris obstacles relative to the apertured cover plate,
FIG. 12 is an exploded perspective view depicting the method for
fabrication of an internally flared rectangular waveguide
flange,
FIG. 13 is an axially foreshortened longitudinal sectional view of
a section of waveguide employing the flanges of FIG. 12 and being
closed at one end by means of a gas tight window,
FIG. 14 is a perspective view similar to that of FIG. 4 depicting
an alternative stamping for the channel portion of the body of a TR
tube,
FIG. 15 is a perspective view of the stamping of FIG. 14 after
bending to form the channel shape,
FIG. 16 is a perspective view of a stamping employed as the cover
plate for closing the open side of the channel of FIG. 15,
FIG. 17 is a plan view of a stamped iris obstacle,
FIG. 18 is a perspective view of the main body portion of a TR tube
employing the components of FIGS. 14-17,
FIG. 19 is a view similar to that of FIG. 14 depicting an
alternative method for making the body of a TR tube,
FIG. 20 is a view similar to that of FIG. 16 depicting an
alternative cover,
FIG. 21 is a view similar to that of FIG. 17 depicting an
alternative stamped waveguide iris obstacle,
FIG. 22 is a perspectie view similar to that of FIG. 18 depicting
an alternative TR tube,
FIG. 23 is an exploded view of a dual waveguide flange made
according to a method of the present invention,
FIG. 24 is a sectional view of the structure of FIG. 23 taken along
line 24--24 in the direction of the arrows.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1-3 there is shown a method for fabricating
a section of rectangular waveguide according to the present
invention. More particularly, a first rectangular metallic sheet 11
is stamped out of metallic sheet stock. Sheet 11 has a width w
corresponding to the sum of twice the height of the waveguide plus
the width of the waveguide. The member has a length 1 corresponding
to the desired length of waveguide to be fabricated. Similarly, a
rectangular cover member 12 is stamped from sheet stock and has a
width b corresponding to the width of the waveguide and a length l
corresponding to the length of the waveguide to be fabricated.
In a typical example of an X-band waveguide, members 11 and 12 are
stamped from 1010-1020 No. 18 gauge cold rolled steel sheet stock.
The stamped cold roll steel members 11 and 12 are then copper
plated.
In the next step as shown in FIG. 2, member 11 is folded or bent
into a generally U-shaped channel having an open side or top
portion. The fold lines 13 and 14 run longitudinally of the member
11 and serve to fold up narrow side wall portions 15 and 16 which
have heights, a, approximately equal to one-half the width b of the
channel. Plate 12 is then positioned over the open side of the
channel and joined along the side edges of the cover 12 to the
upstanding marginal side edges of the channel 11, as by brazing, to
obtain a composite rectangular waveguide 17 as shown in FIG. 3.
The advantage to this method of making a rectangular waveguide, as
contrasted with procuring extruded rectangular waveguide, is that,
in small lot quantities the waveguide section may be made of any
desired length merely by determining the length of the stampings
without having to procure large runs of extruded waveguide which
would then be cut to the proper length. During the brazing step, a
suitable brazing jig, not shown, holds the cover plate 12 in
position relative to the adjoining upper lips of the side walls 15
and 16.
Referring now to FIGS. 4-9 there is depicted a method of the
present invention for fabrication of an X-band TR tube. As shown in
FIG. 4, the waveguide body portion of the TR tube is fabricated in
the same manner as shown in FIG. 1, namely, rectangular members 11'
and 12' are stamped from metallic sheet stock. However in the case
of members 11' and 12' the members are also, at the time they are
stamped, pierced with a certain predetermined pattern of holes or
apertures 18 and 19 to receive certain waveguide obstacles such as
cones. In the case of the bottom U-shaped channel member 11', one
hole 18' is provided in that portion of the member 11' which will
be foldled up to form a side wall of the main body. This hole 18'
is provided for evacuation and gas fill of the TR tube.
A pair of inductive iris obstacles are formed by stamping from cold
roll steel sheet stock material a rectangular member 21 with a
pattern of apertures 22 therein which will form the inductive
irises when the member 21 is folded. Next, the member 21 is folded
along fold lilnes 23-26 such that the resultant obstacle has a
height, a, and a spacing c between a pair of inductive iris
portions 22 of the obstacle. The semicircular end portions of the
apertures 22, when folded, are in registration with holes 18 and 19
in the top and bottom walls of the resultant waveguide.
The obstacle 21 is assembled within the waveguide channel portion
11', as shown in FIG. 7. The obstacle 21 is precisely positioned
therein by means of a suitable assembly jig, not shown, and then
secured in place, as by spot welding at 28 or welding the foot
portions 29 of the obstacle 21 to the bottom wall of the channel
member 11'. The cover plate 12' is then affixed over the open side
of the channel member 11' and cone shaped obstacles 31 are inserted
through the aligned apertures 18 and 19 into the iris openings in
the obstacle 21.
After these elements have been assembled, the assembly is provided
with waveguide flanges 32 at opposite ends. The assembly is then
brazed together by means of brazing wire strategically located
adjacent seams to be formed in the brazed assembly. The resultant
X-band TR tube is shown in FIG. 9. After the brazing step,
waveguide window assemblies, not shown, are sealed across the
openings in opposite flanges 32 and the TR tube is evacuated and
filled with a suitable ionizable medium, in the conventional
manner. An X-band TR tube fabricated according to the method of
FIG. 4-9 results in a substantial cost savings in parts and
materials and avoids substantially all relatively expensive
machining operations.
Referring now to FIGS. 10 and 11 there is shown an alternative
method for fabricating a TR tube particularly suited for S-band.
More particularly, the method of fabrication is similar to that
previously described with regard to FIGS. 4-9 with the exception
that the waveguide iris obstacles are formed in a different manner.
As in the case of obstacle 21 of the previous example, an iris
obstacle 34 is stamped from sheet stock as shown in FIG. 10. The
obstacle 34 includes a central aperture 35 which is to form the
iris opening. The iris opening is generally rectangular with a
semicircular cutout at one end and with a spike structure 36
stamped out of the metal stock projecting axially of the aperture
35. The obstacle 34 has a width b corresponding to the inside width
of the waveguide in which it is to be disposed. A second
semicircular cutout 37 is provided in one end of the member 34.
The member is then folded along fold lines 38 and 39 to form a
generally channel-shaped member which is positioned on its side
transversely within the guide in the manner as indicated in FIG.
11. In a typical example, three such obstacles 34 will be
positioned in side-by-side relation to define three inductive
irises 35 in tandem along the length of the waveguide section. The
semicircular cutouts in the folded members mate with and are
located in registration with three apertures 41 in the cover plate
12 to permit upper cone members to be positioned within the
waveguide in transverse registration with the lower spike members
36 to establish discharge gaps therebetween.
The obstacles 34 are spot welded to the lower channel member 11 in
the manner as previously described with regard to FIG. 7. The
assembly is brazed together to form a gas tight TR tube body.
Waveguide flanges are affixed to opposite ends of the waveguide
body in the manner as will be described in FIGS. 12 and 13.
Referring now to FIGS. 12 and 13 there is shown a waveguide flange
assembly 42 which is fabricated according to the method of the
present invention. More particularly, the flange 42 includes a
first generally rectangular plate 43, as of 10 gauge 1010-1020 cold
rolled steel which is stamped out of sheet stock with a central
rectangular aperture 44 and bolt holes 45. A rectangular axially
directed flange portion 46 is provided at the lip of the central
aperture 44. This flange is formed, according to the present
invention, by stamping three annular ring members 47 from cold
rolled steel sheet stock. The rings 47, in a typical S-band flange
assembly, each have a thickness as of 0.062 inch and a radial width
of 0.10 inch. The inside aperture of each of the rings 47 is
dimensioned to be equal to the inside dimensions of the aperture 44
in flange plate 43. The flange plate 43 and the rings 47 are copper
plated and then overplated with silver. The plated members are then
stacked together in a brazing fixture and brazed in a hydrogen
furnace at 925.degree.C for 5 minutes. The silver serves as a
brazing material. The completed flanges 42 are then brazed to the
opposite ends of the TR tube body in the manner shown in FIG. 13. A
gas tight microwave window assembly 49 is brazed to the inner lip
46 of one of the flange members 43.
The advantage of fabricating the flange 42 according to the present
invention, wherein the stamped parts are brazed together to form
the composite flange structure 42, is that the flange need not be
ground flat as is the case when the internal flange portion 46 is
made by drawing of a stamping.
Referring now to FIGS. 14-18 there is shown an alternative method
for fabricating a TR tube according to the present invention. The
method is similar to that previously described with regard to FIGS.
4-9 with the exception that the iris plates 51, as shown in FIG.
17, are stamped from sheet stock and provided, at the time of
stamping, with tabs 52 at the outer periphery of the iris plate 51.
The bottom wall stamping, as shown in FIG. 14, which is to form the
bottom and sides of the main waveguide body 11, is also stamped
with a pattern of apertures 50 to receive the bottom tab 52 and the
two side tabs 52 on the iris plates 51. The bottom wall stamping 11
is folded along fold lines 13 and 14 to form the bottom and side
walls of the waveguide structure. The cover plate 12, as shown in
FIG. 16, is similarly stamped with a pattern of apertures 55 to
receive the two upper tabs 52 of the iris plates 51. In addition,
circular apertures 56 are punched in transverse registration with
the tab apertures 55 and along the longitudinal center line of the
cover plate 12 to receive the upper cone assemblies 57. The iris
plates 51 are transversely inserted into the channel shaped member
11 and then the cover plate 12 is assembled to capture the
respective iris plates 51 in their proper position. The cover plate
12 is then held in position by a suitable jig and the assembly is
brazed to provide the composite TR tube body as shown in FIG.
18.
Referring now to FIGS. 19-22 there is shown an alternative method
for fabricating a TR tube according to the present invention. The
method is similar to that previously described with regard to FIGS.
14-18 with the exception that the stamping for the cover plate 12",
as shown in FIG. 20, has the same width w as the stamping which is
to form, when folded, the bottom half of the waveguide. The bottom
half is shown in FIG. 19 as stamping 11".
The bottom and top half stamping 11" and 12" are punched at the
time of stamping with a certain pattern of apertures 50 and 55 to
receive waveguide obstacles, such as the tabs 52 of iris plates 61
of FIG. 21. The stampings 11" and 12" are folded along fold lines
13 and 14 and 62 and 63, respectively, such that the upturned side
walls 15 and 16 of the bottom channel 11" extend a distance only
one-half of the height, a, of the waveguide. Similarly, the top
half as folded along fold lines 62 and 63 has downturned side walls
64 and 65 which are downturned by only one-half the height, a, of
the waveguide. Three iris plates 61 are located within the lower
channel 11" and then the cover member or channel 12" is positioned
over the lower channel to close the open side thereof as shown in
FIG. 22.
The assembled waveguide and irises 61 are then held in a suitable
jig and a heliarc weld is made along the two opposed side seams at
the mating lips of the side walls of the lower and upper channel
members 11" and 12" of the assembly. Cone obstacles are then
assembled within the apertures 56 in alignment with the lower spike
portions 36 of the iris plates 61. Windows and flanges are affixed.
Brazing material is positioned along the internal and external
seams and the unit is then brazed in a furnace to produce a gas
tight TR tube body. The method of constructing a TR tube as
described with regard to FIGS. 19-22 is particularly suitable for
fabrication of an L-band TR tube.
Referring now to FIGS. 23 and 24 there is shown a method, according
to the present invention, for fabrication of a dual waveguide
flange assembly 68. The dual waveguide flange 68 is affixed as by
brazing over the end of a pair of side-by-side rectangular
waveguides, not shown. The composite flange 68 is fabricated by
brazing together three stampings 69, 71 and 72 which have been
stamped from cold rolled steel sheet stock. The first stamping 69
comprises a centrally apertured rectangular plate having dimensions
of the rectangular opening 73 corresponding to that required to be
affixed to a pair of side-by-side waveguides. In a typical example,
flange member 69 is stamped from 1010-1020 cold rolled steel of 14
gauge thickness. The flange plate 69 is also stamped or punched at
the time it is stamped from sheet stock with a pattern of bolt
holes 74.
The second stamping 71 is similar to stamping 69 in that the bolt
pattern is the same and the outside dimensions of the rectangular
plate are the same as those of plate 69. However, plate 71 is
apertured with a pair of side-by-side rectangular apertures 75 with
a septum 76 separating the apertures 75. The apertures 75
correspond to the inside dimensions of the rectangular waveguides
to which the flange is to be affixed.
The third stamping 72 is substantially the same as that of the
second stamping 71 with the exception that the septum 76' is
narrower and the side-by-side rectangular apertures 77 have inside
dimensions corresponding to the outside dimensions of the
rectangular waveguide to which they are to be affixed. The
apertures 77 and 75 in respective plates 71 and 72 are coaxially
aligned. The stampings 61-72 are copper plated then overplated with
silver and held together for brazing in the manner previously
described with regard to fabrication of flange 42 of FIG. 12. The
composite flange assembly 68 is then ready to be affixed to dual
waveguide assemblies.
The advantage to the method of fabricating the flange 68 according
to the method of the present invention is that expensive machining
steps are avoided. The cost of a relatively large flange is greatly
reduced utilizing the method of the present invention. Generally
speaking, utilizing the methods of the present invention for
fabricating TR tubes and waveguide components, the direct
manufacturing costs of labor and materials are cut in approximately
half as contrasted with the prior method which utililzed machining
of stampings and extrusions.
* * * * *