Integrated Sheet-Metal Filter Unit for Compact 5G Low-Loss Suppression
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Solution Overview
Problem
Traditional ceramic waveguide (CWG) filters for 5G communication have limitations such as lower Q value, size constraints, poor out-of-band frequency attenuation, and reliability issues, which hinder their use in complex radio systems and wideband radio products.
Innovation Solution
An integrated low-pass and band-pass filter unit formed by electroplated sheet metal with dielectric material coatings, featuring aligned resonators and adjustable coupling structures, to enhance Q value, reduce size and weight, and improve power handling capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If ceramic waveguide (CWG) filters are used to reduce size and weight, then the filter size and weight are reduced, but the Q value decreases and reliability deteriorates
Solution Approach 1:
The patent uses composite material structure by combining sheet metal (conductive material) with dielectric material coating on specific portions of the resonators. This composite approach allows the filter to achieve high Q value through the conductive sheet metal while the dielectric coating enables size reduction and improved power handling, thus resolving the contradiction between size reduction and reliability maintenance
Solution Approach 2:
The patent changes the material parameters by using electroplated sheet metal with specific conductivity and dielectric coating with specific permittivity values. This parameter optimization allows the resonators to maintain high Q value while achieving compact size and improved reliability, overcoming the limitations of traditional CWG filters
2Reliability
If CWG filter size is increased to improve Q value, then the Q value increases, but the size increases which contradicts the design desire of smaller size
Solution Approach 1:
The patent applies local quality by coating only specific portions of the resonators with dielectric material rather than the entire surface. This localized dielectric coating on critical areas of the sheet metal resonators enables Q value enhancement and size reduction simultaneously, avoiding the need to increase overall filter size
Solution Approach 2:
The combination of sheet metal and dielectric material creates a composite resonator structure where the sheet metal provides high conductivity and Q value, while the localized dielectric coating enhances field confinement and allows size reduction, resolving the size-Q value contradiction
3Reliability
If traditional metal FUs are used to achieve good performance and reliability, then reliability improves, but size and cost increase making them unsuitable for MIMO systems
Solution Approach 1:
The patent segments the filter unit into integrated low-pass and band-pass filter functions within a single compact sheet metal structure. This segmentation allows the filter to achieve reliable performance with reduced size compared to traditional separate metal FUs, making it suitable for space-constrained MIMO systems
Solution Approach 2:
The patent merges low-pass and band-pass filter functions into a single integrated unit using shared sheet metal resonators and common dielectric coating. This merging achieves reliable multi-function performance while significantly reducing size and cost compared to traditional separate metal filters
4Object-affected harmful factors
If CWG FUs are soldered with PCB LPF to improve out of band attenuation, then attenuation performance improves, but insertion loss increases and extra coupling occurs
Solution Approach 1:
The patent merges the low-pass filter function directly into the band-pass filter unit using integrated sheet metal resonators that serve dual purposes. This integration eliminates the need for separate PCB LPF connections, maintaining excellent out-of-band attenuation while reducing insertion loss and avoiding extra coupling paths
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 filter unit achieves reduced size and weight, improved reliability, enhanced power handling, and flexible design capabilities, enabling better out-of-band suppression and insertion loss performance for radio frequency signals.
Implementation Method 1
A part of each of the low-pass and band-pass resonators is coated with dielectric material
Implementation Method 2
one or more low-pass resonators and two or more band-pass resonators comprised in the inner cavity. The low-pass and band-pass resonators are integrally formed by electroplated sheet metal material
Data Source
Figure 1a~1b
Figure 2~3
Figure 4a~4b
AI summary
An integrated low-pass and band-pass filter unit (400) comprises an inner cavity (401) formed by a shell (402) of conductive materials; one or more low-pass resonators (411, 412, 413) and two or more band-pass resonators (421, 422, …426) comprised in the inner cavity (401). The low-pass and band-pass resonators (411, 412, 413, 421, 422, …426) are integrally formed by electroplated sheet metal material, and a part of each of the low-pass and band-pass resonators (411, 412, 413, 421, 422, …426) is coated with dielectric material. The two or more band-pass resonators (421, 422, …426) are arranged at two sides of the inner cavity (401) such that at least two resonators are aligned to face each other. The integrated low-pass and band-pass filter unit (400) further comprises a first separator (430) of electroplated sheet metal arranged in the inner cavity (401) between the low-pass resonators (411, 412, 413) and band-pass resonators (421, 422, …426) and a second separator (440) of electroplated sheet metal arranged in the inner cavity (401) between the band-pass resonators at the two sides of the inner cavity 401. The integrated low-pass and band-pass filter unit (400) further comprises an input port (450) to receive a signal to be filtered and an output port (460) to output a filtered signal.