Integral Cavity Microwave Device Screwless Assembly
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Solution Overview
Problem
Existing microwave components require numerous screws for assembly, leading to inefficiencies in production, potential electrical failures due to inter-modulation products, and increased size, weight, and cost, particularly due to complex wiring slots and externally disposed covers or welded heads.
Innovation Solution
The design features an integrally formed cavity with inclined through holes for cable connection, eliminating the need for screws and incorporating a layered or segmented wiring slot configuration for secure cable connection, along with a holding groove and embossment for securing the microwave network circuit, allowing for extrusion-based construction and reduced component size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If numerous screws are used to secure the cavity and cover together, then the assembly reliability is improved, but the production efficiency deteriorates and the device complexity increases
Solution Approach 1:
The cavity and cover are merged into a single integrally formed structure made from a single piece of conductive material. This eliminates the need for multiple screws to secure them together, thereby improving production efficiency while maintaining assembly reliability through the inherent structural integrity of the integral design.
Solution Approach 2:
The cover is extracted as a separate component and eliminated entirely. Instead of having a separate cover that needs to be secured with screws, the cavity is designed as an open structure where the circuit board forms part of the enclosure, removing the fastening requirement entirely.
2Stability of the object's composition
If numerous screws are used for fastening purpose, then the structural stability is improved, but the electrical reliability deteriorates due to inter-modulation products
Solution Approach 1:
The cavity and cover are combined into a single integral structure, eliminating multiple screw connections that could generate inter-modulation products. The structural stability is maintained through the rigid monolithic construction while electrical reliability is improved by removing potential sources of electromagnetic interference.
Solution Approach 2:
The mechanical screw fastening system is replaced with an integral formed structure. This substitution eliminates the mechanical connections that could generate inter-modulation products, thereby improving electrical reliability while maintaining structural stability through the inherent strength of the single-piece construction.
3Ease of operation
If wiring slots are provided on the cavity for welding transmission cable, then the ease of operation is improved, but the device complexity and size increase
Solution Approach 1:
The traditional wiring slots with externally disposed covers are extracted and replaced. Instead of providing complex wiring slots on a closed cavity, the cavity is designed as an open structure where cables can be directly accessed and welded to the circuit board terminals, simplifying the overall structure while maintaining ease of operation.
Solution Approach 2:
Instead of providing wiring slots on a closed cavity structure, the design is inverted by making the cavity open and allowing direct access to the circuit board. This reversal of the traditional approach eliminates the need for complex wiring slot structures while maintaining cable welding ease.
4Stability of the object's composition
If externally disposed cover or welded head is used, then the structural completeness is improved, but the size, weight and cost increase
Solution Approach 1:
The cavity and cover are merged into a single integral structure, eliminating the need for separate covers or welded heads. This reduces the overall weight while maintaining structural completeness through the monolithic design. The single-piece construction also reduces manufacturing cost and simplifies assembly.
Solution Approach 2:
The separate cover component is extracted and eliminated. Instead of having an additional cover that increases weight and complexity, the cavity is designed as an open structure where the circuit board and its terminals provide both the structural enclosure and the cable connection points.
Data Source
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AI summary
A microwave component of cavity type includes an integral cavity and a microwave network circuit disposed in the cavity. The cavity has multiple enclosing walls and a chamber defined by said multiple enclosing walls. The chamber is intended for accommodating the microwave network circuit therein. A wiring slot is defined in at least one of the enclosing walls, and at least one first through hole extended through the chamber is provided on each wiring slot. The microwave component of cavity type features small size, simple structure, and wide application. Furthermore, cost may be reduced, batch production may be achieved, use of fasteners such as screws is avoided, and the passive inter-modulation products caused by fasteners are eliminated, as the microwave component is secured without any screws.