Foldable Cavity Filter Layout for Slim Low-Loss RF Modules
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Solution Overview
Problem
Conventional radio frequency filters for communication devices face challenges in reducing size and weight due to the need for complex joining processes and additional conductive components, which also lead to increased insertion loss.
Innovation Solution
A filter design that uses a foldable conductive base plate to create a cavity and position resonators within, eliminating the need for conventional joining processes and allowing for easier manufacturing and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional joining processes are used to form cavity and position resonators, then structural stability is improved, but manufacturing complexity and insertion loss increase
Solution Approach 1:
The cavity structure and resonator positioning function are merged into a single integrated base plate component. The base plate includes recessions that directly hold the resonators, eliminating the need for separate joining processes and additional structural components. This integration reduces manufacturing complexity while maintaining structural stability through the unified design.
2Reliability
If additional conductive components are installed for coupling, then inductive/capacitive coupling is improved, but weight increases
Solution Approach 1:
The patent extracts and eliminates the need for additional conductive components by utilizing the base plate itself as the coupling medium. The recessions in the base plate create direct electromagnetic coupling paths between resonators, removing the weight of separate inductive/capacitive coupling components while maintaining the necessary coupling characteristics.
3Manufacturing precision
If filter tuning cover is deformed through punching process, then band-pass characteristics are improved, but thickness direction size is limited
Solution Approach 1:
The patent shifts the tuning mechanism from vertical deformation (punching the filter tuning cover in the thickness direction) to horizontal positioning. Resonators are positioned at specific lateral locations within recessions of the base plate, allowing band-pass characteristic tuning through lateral placement rather than vertical compression, thereby reducing the thickness direction size.
4Manufacturing precision
If resonators are positioned to protrude in thickness direction, then resonance characteristics are improved, but overall device thickness increases
Solution Approach 1:
The resonators are nested within recessions of the base plate structure. Instead of protruding freely in the thickness direction, the resonators are contained within the recession depth, allowing their resonance characteristics to be optimized while limiting their protrusion. This nesting approach maintains resonance performance while constraining the overall device thickness.
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 reduces insertion loss and enables a thinner, lighter antenna device design by simplifying the manufacturing process and eliminating the need for additional conductive components.
Implementation Method 1
a base plate made of a conductive material, and manufactured in an unfolded state, the base plate being configured foldable such that, upon folding, a cavity is formed inside
Implementation Method 2
Each resonator has a structure in which a dielectric resonance element (DR) or a metallic resonance element is installed in a cavity... allowing only an electromagnetic field of a unique frequency corresponding to a processing frequency band to exist within the associated cavity, thereby enabling high-frequency resonance
Data Source
AI summary
Disclosed herein may be a filter for communication devices. The filter may include a base plate made of a conductive material, manufactured in an unfolded state and configured to be foldable such that, upon folding, a cavity is formed inside while simultaneously positioning a plurality of resonators to protrude by a set length in a thickness direction or a width direction in the cavity. The plurality of resonators each have a distal end portion having a wider width than a remaining portion, and include a resonance characteristic end formed by curling opposite widthwise ends of the distal end portion in a rounded shape in one thickness direction from a leading end of the remaining portion. The aforementioned configuration provides advantages of facilitating a slim product design, reducing insertion loss, and enhancing resonance characteristics.