Ceramic Filter Differential Glass Frit Coating
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Solution Overview
Problem
Conventional ceramic filters have a low Q factor compared to air dielectric filters, limiting their performance and mechanical strength, and they often require additional shielding to reduce electromagnetic interference.
Innovation Solution
A ceramic filter design featuring a dielectric block with a patterned top surface, through-holes, and walls with selective coatings of glass frit, where the first coating has at least 0.5% more glass frit than the second coating, enhancing mechanical strength and Q factor by reducing resistive losses and improving adhesion to a printed circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional ceramic filters use uniform glass frit coating, then manufacturing is simplified, but Q factor remains low due to high resistive losses in conducting paths
Solution Approach 1:
The patent applies different glass frit compositions to different regions of the ceramic filter. Specifically, the first glass frit coating is applied to the bottom surface, side surfaces, outer surface, and roof, while the second glass frit coating is applied to the patterned region, through-hole, and inner surface. This local differentiation allows optimization of electrical properties in conducting paths while maintaining manufacturing feasibility.
Solution Approach 2:
The patent uses composite material structures by combining two different glass frit coatings with distinct compositions. The first glass frit has a composition optimized for mechanical strength and adhesion, while the second glass frit has a composition optimized for low resistive losses and high Q factor in the conducting paths. This composite approach enables simultaneous achievement of mechanical integrity and electrical performance.
2Strength
If ceramic filters use higher glass frit content for better adhesion, then mechanical strength improves, but Q factor decreases due to increased resistive losses
Solution Approach 1:
The patent applies different glass frit compositions to different regions of the ceramic filter. Specifically, the first glass frit coating is applied to the bottom surface, side surfaces, outer surface, and roof, while the second glass frit coating is applied to the patterned region, through-hole, and inner surface. This local differentiation allows optimization of electrical properties in conducting paths while maintaining manufacturing feasibility.
Solution Approach 2:
The patent uses composite material structures by combining two different glass frit coatings with distinct compositions. The first glass frit has a composition optimized for mechanical strength and adhesion, while the second glass frit has a composition optimized for low resistive losses and high Q factor in the conducting paths. This composite approach enables simultaneous achievement of mechanical integrity and electrical performance.
3Reliability
If ceramic filters use metallic coatings for conducting paths, then electrical conductivity is achieved, but electromagnetic interference increases requiring additional shielding
Solution Approach 1:
The patent converts the potentially harmful effect of metallic coatings generating electromagnetic interference into a beneficial outcome by using the glass frit-based conducting paths. The glass frit coatings provide sufficient electrical conductivity for filter operation while inherently suppressing electromagnetic interference, eliminating the need for additional shielding structures and simplifying the overall device design.
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 increases the Q factor of ceramic filters to levels similar to air dielectric filters, enhances mechanical strength, and reduces power dissipation, allowing for higher power handling and improved electromagnetic interference suppression without external shielding.
Implementation Method 1
The first coating including glass frit has an amount of glass frit that is at least 0.5% greater than the amount of glass frit in the second coating including glass frit, the first coating enhancing mechanical strength and Q factor by reducing resistive losses and improving adhesion to a printed circuit board
Implementation Method 2
The first coating including glass frit has an amount of glass frit that is at least 0.5% greater than the amount of glass frit in the second coating including glass frit, the first coating enhancing mechanical strength and Q factor by reducing resistive losses
Data Source
AI summary
The present application is directed to a filter and methods of making the same. The filter includes a block of dielectric material with a top surface including a patterned region, a bottom surface, and side surfaces. The filter also includes a through-hole extending through the block from the top surface to the bottom surface. The through-hole is partially surrounded by the patterned region. The filter also includes a wall extending from the top surface, the wall having an inner surface, an outer surface, and a roof. The bottom surface, side surfaces, outer surface, and roof have a first coating including glass frit. The patterned region, through-hole and inner surface have a second coating including glass frit. The glass frit in the first coating is at least 0.5% greater than the glass frit in the second coating. The application is also directed to a system including a printed circuit board and a filter.