Abstract
The design of a WR10 waveguide coupling structure is presented. Electrically, it consists of an $E$ -plane (series) T-junction and a quarter-wave section. The resulting coupling factor is nearly constant over the entire ${W}$ -band. A milled split-block network and a wire-eroded metal plug-in, which is inserted into a groove in the split block, implement the coupling structure. This modular design makes the coupling factor easily configurable and enables the realization of quarter-wave section heights in the range of tens of micrometers. The plug-in is fabricated by wire erosion, a machining technique based on electrical discharge (spark machining). This enables precise adjustment of the height and length of the quarter-wave section (±2- $\mu \text{m}$ contour accuracy) and provides polishedlike surface quality ( $R_{\mathrm {z}} =2.1\,\,\mu \text{m}$ ). Hints for the manufacturing of the metal plug-in are given; full-wave simulations as well as measurements of ${W}$ -band prototype structures are evaluated, and the possibility of a postfabrication adjustment of the metal plug-ins is shown.
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