Compact Double-Cell Hyperfrequency Circulator via Co-Sintered Stacking
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Solution Overview
Problem
Microwave circulators are bulky and difficult to integrate with microelectronic circuits due to their size and manufacturing costs, and existing solutions to improve insulation performance increase the component's surface area, making them less suitable for compact applications.
Innovation Solution
A method involving a co-sintered three-plate structure with ferrite and dielectric or weakly magnetic material layers, where each cell has a core surrounded by the respective material, and a main conductor via connecting the cells, with secondary conductor vias for shielding, reducing the overall surface area and height by burying access and connection tracks within the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional separate ferrite devices are used, then insulation performance is adequate, but the component is bulky and difficult to integrate with microelectronic circuits
Solution Approach 1:
The patent combines multiple ferrite devices into a single integrated component with a common ground plane and shared magnetic shielding structure. The first and second ferrite devices are positioned on opposite sides of the ground plane, forming a compact assembly that reduces overall volume while maintaining isolation performance. The magnetic shielding structure integrates both E-shape and I-shape configurations to provide comprehensive shielding for the entire assembly.
Solution Approach 2:
The patent implements nested magnetic shielding where an inner I-shape magnetic shielding structure is positioned within the outer E-shape magnetic shielding structure. This nested configuration provides multiple layers of magnetic isolation within a compact volume, effectively shielding the ground plane and surrounding areas from magnetic fields generated by the ferrite devices.
2Reliability
If double-cell components are used to increase insulation performance, then insulation is improved, but the surface area occupied is multiplied by two
Solution Approach 1:
The patent transitions from a planar arrangement where double-cell components would occupy twice the surface area to a three-dimensional configuration using a ground plane. The first ferrite device is positioned on one side of the ground plane and the second ferrite device on the other side, effectively utilizing the vertical dimension to achieve dual-cell insulation performance without doubling the footprint area.
Solution Approach 2:
The patent merges two ferrite device cells into a single integrated structure that shares a common ground plane and magnetic shielding. This consolidation allows both cells to occupy the same lateral footprint by stacking them vertically on opposite sides of the ground plane, thereby maintaining insulation performance while halving the required surface area compared to separate planar arrangements.
3Volume of moving object
If ferrite devices are placed close together for compactness, then volume is reduced, but magnetic field interference increases
Solution Approach 1:
The patent introduces a ground plane as an intermediary barrier positioned between the first and second ferrite devices. This ground plane acts as a magnetic shield that blocks magnetic field lines from one device from reaching the other, effectively eliminating magnetic field interference while allowing the devices to be positioned close together for compact volume.
Solution Approach 2:
The patent employs composite magnetic shielding structures combining E-shape and I-shape magnetic shielding materials. These composite shielding structures are strategically positioned to contain and direct magnetic fields, preventing interference between adjacent ferrite devices while maintaining compact overall dimensions. The composite shielding provides both lateral and vertical magnetic field containment.
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
This approach allows for the production of double-cell circulators with a surface area twice as small as traditional methods, reducing the component's size and volume while maintaining insulation performance and power handling capabilities.
Implementation Method 1
The operation of these microwave circulators is based on the non-reciprocal effect of a magnetically saturated ferrite.
Implementation Method 2
Documents US 2002/135434 A1, XP000315333 and WO 02/099924 A1 disclose circulators with two superposed ferrite cells... the document WO 2012/042168 A1 discloses the fixing of several layers of ferrite by cosintering
Data Source
Figure 1~3a
Figure 3b~4
Figure 5~6
AI summary
The invention relates to a microwave circulator comprising at least: - the superposition of a first cell and a second cell, each cell comprising: o a ferrite core surrounded by dielectric material, said core and said dielectric or weakly magnetic material being enclosed; o at least two access tracks and one connecting track joined together at the level of the ferrite core, on an active face of the cell; - at least one cell connection enabling the electrical connection of said connecting track of said first cell to said connecting track of said second cell. - said superposition comprising a ground plane located between said active faces of said cells, the whole being assembled by co-sintering. The invention also relates to a method for manufacturing a double-cell circulator of the invention.