Cavity Filter Assembly Using Force-Fit Resonator Frames
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Solution Overview
Problem
Conventional radio frequency filters face challenges in reducing thickness, increasing weight due to additional conductor components, and suffer from high insertion loss and low productivity in manufacturing, especially when using heterogeneous materials for resonators.
Innovation Solution
A filter design where the filter body is manufactured by a deep drawing press process, with a resonator frame of a heterogeneous material forcibly fitted and soldered into a homogeneous lower cover panel to shield the cavity, minimizing insertion loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a welding method is applied to couple resonators made of heterogeneous materials, then assembly is achieved, but insertion loss increases significantly
Solution Approach 1:
The patent replaces the welding method (thermal/chemical process) with a mechanical coupling method using coupling members that physically connect resonators through holes in the partition wall. This mechanical coupling avoids the high insertion loss associated with welding heterogeneous materials while achieving stable assembly.
2Reliability
If additional conductor components are installed to enhance coupling characteristics, then coupling performance improves, but filter weight increases greatly
Solution Approach 1:
The patent merges the coupling function with the existing partition wall structure by installing coupling members through holes in the partition wall. This integrates the coupling mechanism into the structural framework rather than adding separate conductor components, achieving enhanced coupling characteristics without significantly increasing filter weight.
Solution Approach 2:
The partition wall serves multiple functions: it provides structural separation between resonators and simultaneously serves as the mounting structure for coupling members. This multi-functionality eliminates the need for additional dedicated coupling components, reducing overall weight while maintaining coupling performance.
3Length of moving object
If dielectric ceramic filter is used to minimize thickness, then product slimness is achieved, but productivity decreases due to molding method limitations
Solution Approach 1:
The patent uses composite construction with metal partition walls and coupling members instead of monolithic dielectric ceramic. This allows the use of conventional metal forming techniques (pressing, punching, bending) which have higher productivity and flexibility, while achieving the required thin profile through optimized structural design.
4Reliability
If cavity shape is pre-manufactured according to final frequency design, then frequency stability is ensured, but variability in frequency tuning design decreases
Solution Approach 1:
The patent introduces adjustable coupling members that can be positioned at different locations and orientations within the partition wall holes. This dynamic adjustability allows frequency tuning after assembly while maintaining the stable pre-manufactured cavity shape, providing both frequency stability and tuning variability.
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 design improves communication device reliability and productivity by reducing insertion loss and enabling stable coupling without welding, while allowing for flexible frequency tuning.
Implementation Method 1
a resonator frame of a second material, which is coupled to the lower cover panel and comprises a plurality of resonant bars extending in a predetermined length toward a top surface of the filter body
Implementation Method 2
the surroundings of the plurality of fitting through holes are fixed within the cavity through soldering and coupling
Data Source
AI summary
The present invention relates to a filter for a communication device, and in particular, to a filter comprising: a filter body including a cavity that is a dielectric filling space and has an open bottom; a lower cover panel made of a first material and coupled to shield the open bottom of the filter body; and a resonator frame made of a second material, wherein the lower end of the resonator frame is coupled by being forcibly fit into a plurality of fitting through-holes that are formed in the lower cover panel so as to pass through the inside and outside of the cavity and provided, spaced apart in the longitudinal direction, in two or more rows in the width direction, and then the surroundings of the plurality of fitting through-holes are fixed inside the cavity through solder bonding, thus providing the advantage of minimizing insertion loss within the cavity.