Stepped Cavity Filter Structure for Lower Insertion Loss
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Solution Overview
Problem
The manufacturing of cavity filters is challenging due to the need for specific resonant cavity dimensions and volumes, which affect filtering performance and complicate the manufacturing process.
Innovation Solution
A cavity filter design with a resonant cavity featuring a plurality of extension sections on the inner wall, inclined towards the outer wall, increasing the cavity volume while reducing outer dimensions and weight, and simplifying the demolding process during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the resonant cavity has a certain depth and volume to ensure filtering performance, then the filtering performance is improved, but the manufacturing complexity increases
Solution Approach 1:
The inner wall of the resonant cavity is divided into multiple extension sections (first, second, third, and fourth extension sections) with different inclination angles. This segmentation allows each section to be optimized independently for both performance and manufacturability, resolving the contradiction between filtering performance and manufacturing complexity.
Solution Approach 2:
Different extension sections have different inclination angles tailored to their specific positions and functional requirements. The first extension section has a larger inclination angle for easier demolding, while subsequent sections have progressively smaller angles to maintain filtering performance. This local optimization resolves the contradiction by applying different quality standards to different parts of the same structure.
2Reliability
If the resonant cavity volume is increased to reduce insertion loss, then the filtering performance is improved, but the outer dimensions and weight increase
Solution Approach 1:
The extension sections are nested within the outer contour of the shell portion, creating a stepped internal structure that increases the resonant cavity volume without proportionally increasing the outer dimensions. This nested configuration allows the cavity to expand inward rather than outward, reducing weight while maintaining performance.
Solution Approach 2:
Instead of increasing cavity volume by expanding the outer dimensions uniformly in all directions, the extension sections utilize the radial dimension by inclining toward the outer wall. This dimensional approach increases internal volume while keeping the external footprint and weight relatively controlled.
3Reliability
If the resonant cavity volume is increased to reduce insertion loss, then the filtering performance is improved, but the outer dimensions increase
Solution Approach 1:
The extension sections are nested within the outer contour of the shell portion, creating a stepped internal structure that increases the resonant cavity volume without proportionally increasing the outer dimensions. This nested configuration allows the cavity to expand inward rather than outward, reducing weight while maintaining performance.
4Ease of manufacture
If the shell portion is cast with traditional structure, then the manufacturing is simplified, but the demolding difficulty increases
Solution Approach 1:
The first extension section has a specifically designed larger inclination angle that exceeds the draft angle requirement, creating a local quality difference that facilitates demolding. This localized design change enables the entire shell portion to be easily demolded while maintaining the overall casting process simplicity.
Data Source
AI summary
The embodiments of the present disclosure disclose a cavity filter. An inner wall of a resonant cavity is provided with a plurality of non-coplanar extension sections inclined toward an outer wall; and meanwhile, each extension section gradually extends toward an end cover from a bottom shell. Thus, a volume of the resonant cavity is increased, making an insertion loss smaller; an outer dimension of the cavity filter is further reduced, making an overall weight lighter; and meanwhile, during casting of a shell portion of the cavity filter, the difficulty of demolding is reduced.