Millimeter Wave Filter Fine-Tuning Structure for Frequency Precision
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Solution Overview
Problem
Conventional manufacturing processes for millimeter wave filters often result in resonant frequency deviations due to limited physical tolerance, leading to reworks and low yield rates, especially in the critical 5G frequency band.
Innovation Solution
A millimeter wave filter fine-tuning structure featuring a resonant cavity with fine-tuning cavities and adjusting screws at its edges, allowing for precise adjustment of the resonant frequency without deep insertion loss, utilizing metal screws with projection areas to control depth and prevent significant frequency shifts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing processes are used for millimeter wave filters, then manufacturing simplicity is maintained, but resonant frequency deviation occurs due to limited physical tolerance
Solution Approach 1:
The filter structure is divided into a main resonant cavity and separate fine-tuning cavities with adjusting screws. This segmentation allows the manufacturing process to focus on the main cavity while the fine-tuning components can be adjusted separately to correct frequency deviations, thus improving manufacturing precision without significantly complicating the overall manufacturing process.
Solution Approach 2:
The patent introduces adjustable fine-tuning cavities with screws that can be dynamically adjusted after manufacturing. This dynamic adjustment capability allows the resonant frequency to be fine-tuned to compensate for manufacturing tolerances, improving frequency precision while keeping the base manufacturing process relatively simple.
2Measurement precision
If adjusting screws are inserted deeply into the resonant cavity to correct frequency deviation, then frequency adjustment precision is improved, but insertion loss increases significantly
Solution Approach 1:
The patent extracts the fine-tuning function from the main resonant cavity by creating separate fine-tuning cavities positioned at the edges. This allows frequency adjustment to be performed outside the main cavity, achieving frequency precision without the energy loss associated with deep insertion into the resonant cavity.
Solution Approach 2:
The fine-tuning cavities act as intermediary structures between the main resonant cavity and the adjusting screws. These intermediary cavities allow the screws to influence the resonant frequency without requiring deep insertion into the main cavity, thus achieving frequency adjustment precision while minimizing insertion loss.
3Manufacturing precision
If manufacturing tolerance is tightened to reduce resonant frequency deviation, then frequency precision is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent incorporates fine-tuning cavities and adjusting screws as preliminary corrective measures built into the manufacturing process. This allows manufacturers to produce parts with standard tolerances and then use the fine-tuning mechanism to achieve the required frequency precision, eliminating the need for tight manufacturing tolerances and simplifying the manufacturing process.
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 solution enables accurate frequency adjustment, reducing the need for reworks and improving manufacturing yield by allowing on-site correction of resonant frequency deviations, thereby enhancing production efficiency and reducing labor and time losses.
Implementation Method 1
the distance between the adjusting screws and the resonant cavity is used to adjust the resonant frequency of the filter
Data Source
AI summary
A millimeter wave filter fine-tuning structure includes a resonant cavity, a fine-tuning cavity disposed at the edge of the resonant cavity, a fine-tuning cavity coupled to the resonant cavity, and plural adjusting screws disposed and inserted in the fine-tuning cavity, and the distance between the adjusting screws and the resonant cavity may be used to adjust the resonant frequency of the filter.