3D Signal Coupler Layout for Low-Loss High-Directivity Coupling

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Solution Overview

Problem

Existing high-frequency signal couplers, particularly those used in car radar systems, face challenges in achieving high directivity and low insertion loss while maintaining a compact size, as traditional ¼ lambda transmission lines result in large device size and high signal transmission losses.

Innovation Solution

A signal coupler design incorporating a substrate with multiple layers and strategically positioned transmission lines for both edge-coupled and broadside-coupled electromagnetic coupling, allowing for compact size and low insertion loss, with the main-transmission-line spanning across multiple layers to enhance coupling efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If traditional ¼ lambda transmission lines are used for signal coupling, then coupling function is achieved, but device size becomes large and insertion loss increases

Engineering Contradiction:
Improveinsertion lossVSAvoidtransmission line length
Core Design Contradiction:
Loss of energyVSLength of stationary object

Solution Approach 1:

The patent transitions from planar transmission line coupling to three-dimensional vertical coupling by stacking multiple conductor layers (first, second, and third conductor layers) at different heights. The coupled transmission line extends vertically through multiple layers with conductor portions arranged at different positions in the vertical direction, enabling compact coupling without requiring long horizontal transmission lines.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent embeds multiple conductor portions within a stacked configuration where the first, second, and third conductor layers are nested vertically. The coupled transmission line is formed by conductor portions in different layers that are galvanically connected, creating a compact nested structure that achieves coupling functionality in a reduced spatial footprint.

Inventive Principle:
Principle #7Nested doll (Nesting)

2Length of stationary object

If transmission line length is reduced for compact size, then device size decreases, but coupling efficiency and directivity deteriorate

Engineering Contradiction:
Improvetransmission line lengthVSAvoidcoupling directivity
Core Design Contradiction:
Length of stationary objectVSReliability

Solution Approach 1:

The patent achieves adequate coupling strength with short transmission lines by utilizing vertical separation between conductor layers. The coupled transmission line employs conductor portions at different vertical positions (first, second, and third conductor layers) that provide electromagnetic coupling without requiring long horizontal paths, thereby maintaining compact size while ensuring sufficient coupling directivity.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent optimizes coupling by strategically positioning conductor portions at specific vertical locations within the stacked layers. The first, second, and third conductor layers are arranged with specific spacing and overlap configurations to maximize electromagnetic interaction locally, enabling effective coupling with minimal transmission line length.

Inventive Principle:
Principle #3Local quality

3Length of stationary object

If multi-layer structure is implemented for compact coupling, then device size reduces, but manufacturing complexity increases

Engineering Contradiction:
Improvetransmission line lengthVSAvoidlayer structure complexity
Core Design Contradiction:
Length of stationary objectVSDevice complexity

Solution Approach 1:

The patent divides the transmission line into multiple discrete conductor portions arranged in separate layers (first, second, and third conductor layers). Each conductor portion can be independently formed and positioned, allowing modular manufacturing processes such as separate deposition and patterning steps for each layer, which simplifies the fabrication of complex multi-layer structures.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The stacked conductor layers serve multiple functions: they provide electromagnetic coupling between the main and coupled transmission lines, enable galvanic connections through vertical stacking, and allow independent optimization of each layer's geometry. This multi-functional design reduces the need for additional specialized components or structures.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution achieves high coupler directivity and low insertion loss with reduced size and variation in the coupling factor, making it suitable for high-frequency applications like car radar systems.

Implementation Method 1

the main-transmission-line and the coupled-transmission-line are electromagnetically coupled to each other

Methodology Applied
Scientific EffectElectromagnetic coupling: Electromagnetic Induction

Implementation Method 2

the first-portion, the second-portion and the third-portion are galvanically connected together

Methodology Applied
Scientific EffectGalvanic connection: Conduction (electrical)

Data Source

PatentUS12063057B2Signal coupler
Publication Date: 2024.08.13 NXP USA INC
  • US12063057B2 patent drawing
  • US12063057B2 patent drawing
  • US12063057B2 patent drawing

AI summary

A signal coupler (100) comprising: a main-transmission-line (114) that extends in a longitudinal direction within a substrate (102) between an input port and an output port; and a coupled-transmission-line (116) that extends in the longitudinal direction within the substrate (102) between a coupled port and a termination port. The coupled-transmission-line (116) is in a second layer (110). The main-transmission-line (114) comprises a first-portion (120) in a first layer (108), a second-portion (122) in a second layer (110), and a third-portion (124) in a third layer (112). At least part of the first-portion (120) is spaced apart from the coupled-transmission-line (116) in a depth direction. At least part of the second-portion (122) is spaced apart from the coupled-transmission-line (116) in the depth direction. At least part of the third-portion (124) is spaced apart from the coupled-transmission-line (116) in the depth direction.