Additively manufactured cluster connector

Patent metadata

Field	Value
Publication number	US-12362450-B2
Application number	US-202217818929-A
Country	US
Kind code	B2
Filing date	Aug 10, 2022
Priority date	Aug 10, 2022
Publication date	Jul 15, 2025
Grant date	Jul 15, 2025

Abstract

Described herein is an apparatus and a method for a cluster connector. The cluster connector comprises at least three coaxial-cable core conductors formed in an additive manufacturing process; a dielectric around each of the three coaxial-cable core conductors, formed in the additive manufacturing process; a metallic shield around each dielectric, formed in the additive manufacturing process; at least one stub on each metallic shield, formed in the additive manufacturing process; and a common ground connection connected to each metallic shield, formed in the additive manufacturing process.

First claim

What is claimed is:

1. An additively manufactured cluster connector, comprising:
at least three coaxial-cable core conductors;
a dielectric around each of the at least three coaxial-cable core conductors;
a metallic shield around each dielectric;
at least one stub on each metallic shield; and
a common ground connection connected to each metallic shield.

2. The additively manufactured cluster connector of claim 1 , wherein the at least three coaxial-cable core conductors, the dielectric, the metallic shield, the at least one stub, and the common ground connection are manufactured using a three dimensional (3D) process, wherein 3D printing comprises stereolithography (SLA), direct light processing (DLP), and/or powder bed fusion.

3. The additively manufactured cluster connector of claim 1 , wherein the at least one stub is radially flared with a taper.

4. The additively manufactured cluster connector of claim 3 , wherein the taper is one of exponential, triangular, or Klopfenstein.

5. The additively manufactured cluster connector of claim 1 , wherein the at least one stub has a length of approximately ¼ th of a calculated wavelength at a center frequency of operation of an antenna connected to the cluster connector.

6. The additively manufactured cluster connector of claim 1 , wherein the at least one stub on one metallic shield comprises two stubs that are oriented on opposite sides of the metallic shield and the at least one stub on adjacent metallic shields are oriented +/−90 degrees from each other.

7. The additively manufactured cluster connector of claim 1 , wherein each of the metallic shields has a surface roughness in an order of a skin depth, where the skin depth is a depth of maximum current concentration at a particular frequency.

8. The additively manufactured cluster connector of claim 1 , wherein the at least one stub and each of the metallic shields has a Roughness Average (RA) of 5-10 microns.

9. The additively manufactured cluster connector of claim 1 , wherein the at least three coaxial-cable core conductors are bent.

10. The additively manufactured cluster connector of claim 1 , further comprising:
a cavity; and
an absorber.

11. A method of fabricating a cluster connector, comprising:
forming a core conductor for at least three coaxial conductors using an additive manufacturing process;
forming a dielectric around each core conductor using an additive manufacturing process;
forming a metallic shield around each core dielectric using an additive manufacturing process;
forming at least one stub on each metallic shield using an additive manufacturing process; and
forming a common ground connection to each metallic shield using an additive manufacturing process.

12. The method of claim 11 , wherein the additive manufacturing process used to form the core conductor, the dielectric, the metallic shield, the at least one stub, and the common ground connection for each of the at least three coaxial conductors is a three dimensional (3D) printing process that comprises at least one of stereolithography (SLA), direct light processing (DLP), and powder bed fusion.

13. The method of claim 11 , wherein the at least one stub is radially flared with a taper.

14. The method of claim 13 , wherein the taper is one of exponential, triangular, or Klopfenstein.

15. The method of claim 11 , wherein the at least one stub has a length of approximately ¼ th of a calculated wavelength at a center frequency of operation of an antenna connected to the cluster connector.

16. The method of claim 11 , wherein the at least one stub on one metallic shield comprises two stubs that are oriented on opposite sides of the metallic shield and the at least one stub on adjacent metallic shields are oriented +/−90 degrees from each other.

17. The method of claim 11 , wherein each of the metallic shields has a surface roughness in an order of a skin depth, where the skin depth is a depth of maximum current concentration at a particular frequency.

18. The method of claim 11 , wherein the at least one stub and each of the metallic shields has a Roughness Average (RA) of 5-10 microns.

19. The method of claim 11 , wherein the at least three coaxial conductors are bent.

20. The method of claim 11 , further comprising:
forming a cavity using an additive manufacturing process; and
filling at least a portion of the cavity with an absorber.

Assignees

• Raytheon Co

Inventors

• Herndon Mary K
• Rahman Nahid
• Anderson Russell
• Lovaasen John David
• Palumbo David Joseph
• Cason Michael Wayne

Classifications

• H01Q5/25

  Ultra-wideband [UWB] systems, e.g. multiple resonance systems; Pulse systems · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• H01R2103/00

  Two poles · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B22F7/08

  with one or more parts not made from powder {(B22F7/062 takes precedence)} · CPC title